DOW ™ Ultrafiltration Product Manual

4. DOW ULTRAFILTRATION SYSTEM DESIGN

4. 1. Introduction

The Ultrafiltration system design software is a powerful tool that allows to size new
systems or evaluate the performance of existing ones. In order to design a new
Ultrafiltration system it is important to understand the main inputs needed to get an
accurate and optimized design. These inputs include information about the feed water
source (e.g., municipal, seawater, wastewater, well water or surface water), quality (refer
to Section 2.1 of this document), temperature range and required feed flow or net plant
output. On the other hand, the final application of the project is of interest, as in the case
of drinking water applications, specific DOW™ UF modules must be used (refer to Section
3.3. of this document).

For a given feed water type and quality, the appropriate design guidelines must be
applied. These design guidelines have been created based on extensive experiences and
references in similar waters. The design guidelines include suitable operating flux,
duration of the filtration cycles or frequency of the chemical cleanings. Further
information on Ultrafiltration system operation can be found in Sections 5 and 6 of this
document.

Once all this information is introduced in the system design software, it will populate a
detailed Ultrafiltration System Design report, which includes a general process flow
diagram, module selection, sizing and quantity of trains, sizing of water and chemical
tanks, process parameters and sequence tables, as well as estimations for chemical and
energy consumption, among others.

4. 2. System design software

Dow Water & Process Solutions has designed Water Application Value Engine (WAVE) – a
digital modeling tool that will save time and increase efficiency for evaluating
components as well as designing water treatment systems. The innovative modeling
software combines ultrafiltration membranes, reverse osmosis membranes and ion
exchange resins (IER) into one fully integrated tool.

The WAVE technology uses a powerful hydraulic modeling calculation engine which
improves the accuracy of the model. WAVE capabilities help engineers and original
equipment manufacturers (OEM) configure water treatment components better and
faster through integrating all DW&PS technologies into one tool - allowing for easier
iterations as the design process proceeds. The WAVE tool also offers accurate water
quality predictions for multiple components simultaneously – reducing calculation errors
and data re-entry from one calculation tool to another.

More information about WAVE can be found at www.dowwaterandprocess.com.

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5. DOW ULTRAFILTRATION PROCESS DESCRIPTION

The basic operating conditions for the DOW™ Ultrafiltration modules are shown in Table
8 below. Operating parameters for the cleaning steps are provided in Section 6.

Table 8. DOW™ Ultrafiltration Modules Operating Conditions

Operating Conditions SI US
Maximum Inlet Feed Pressure
SFP/D-2660, -2860, -2880
SFP/D-2860XP, -2880XP 6.25 bar @ 20°C 90.65 psi @ 68°F
IP/IPD-51 and IP/IPD-77
IP/IPD-51XP and IP/IPD-77XP
Operating TMP (Maximum) 2.1 bar 30.50 psi
Backwash TMP (Maximum) 2.5 bar 36.25 psi
Operating Air Scour Flow (Recommended) 12 Nm3/h/module 7 scfm/module
Air Scour Pressure 0.35 – 2.5 bar 5.0 – 36.25 psi
Filtrate Flux @25°C 40 – 110 LMH 24 – 65 gfd
Temperature 1 – 40°C 34 – 104°F
Operating pH Range 2 - 11
NaOCl, Cleaning Maximum 5,000 ppm

At initial plant start-up the modules must be flushed in order to remove any residual
storage chemicals or air trapped during the module installation. This flush occurs on the
outside of the fibers, i.e., no filtrate is produced. Once the initial flush is done, the plant
can begin producing filtrate. When starting the initial filtration cycle the flow should be
slowly increased before being put into operation at the design conditions.

5. 1. Filtration

Ultrafiltration systems are most of the time in Filtration mode while in operation. The
feed water is pumped through the membrane and is converted to filtrate. Typically all
feed is converted to filtrate, in what is referred as dead-end filtration (as opposed to
cross-flow filtration where a fraction of the feed leaves the system as reject). Filtration
cycles typically range from 20 – 90 minutes, depending on the feed water source and
quality. Figure 20 shows a diagram of the Filtration step in DOW™ Ultrafiltration
Modules.

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Figure 20. Filtration Step for DOW™ Ultrafiltration Modules

Ultrafiltration systems are typically designed to operate at constant flowrate. As the

solids build on the membrane surface, the transmembrane pressure (TMP) increases and
eventually the foulants must be removed through a Backwash sequence. The Backwash
sequence is generally initiated based on time. Alternatively, it can be initiated based on
volume of filtrate or TMP set point (the latter is more appropriate for highly variable feed
water quality). The Backwash sequence includes Air Scour, Gravity Drain, Backwash
through the module top outlet, Backwash through the module bottom outlet and a final
Forward Flush or rinse.

5. 2. Air Scour

The Air Scour step is used to loosen particulates deposited on the outside of the
membrane surface. Oil-Free air is introduced through the bottom of the module creating a
stream of ascending bubbles which help to scour material off the membrane. Displaced
water volume is allowed to discharge through the top port of the module for disposal, as
shown in Figure 21. After a minimum of 20 – 30 seconds of continuous Air Scour, the
module is drained by gravity.

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Figure 21. Air Scour Step for DOW™ Ultrafiltration Modules

5. 3. Gravity Drain

Once the Air Scour step is finished, the module must be drained by gravity in order to
flush out of the system the material dislodged from the membrane surface by the
preceding air scour step, as shown in Figure 22. The duration of this step will depend on
the system volume and piping layout, but it is typically set to 30 – 60 seconds. If gravity
drain is not possible due to the system configuration, or it takes too long, it can be
substituted by a forced flush through the bottom outlet of the module using the backwash
pump, however this will consume more water and energy.

Figure 22. Gravity Drain Step for DOW™ Ultrafiltration Modules

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5. 4. Backwash Top

After the gravity drain step, the backwash step is initiated. Filtrate water is pumped
backwards, i.e., from the inside to the outside of the fibers, in order to push the
accumulated material off the membrane. Then it is flushed out to waste through the top
module outlet (see Figure 23). The Backwash flux ranges from 100 – 120 LMH, and the
duration of the step is 30 – 45 seconds. Sometimes, depending on the application,
chlorine might be added to the backwash stream to help remove foulants or inhibit
microbiological activity. Air scour can be combined with the Backwash Top step to
increase cleaning effectiveness.

Figure 23. Backwash Top Step for DOW™ Ultrafiltration Modules

5. 5. Backwash Bottom

After the Backwash Top step, the filtrate continues to flow from the inside of the fiber to
the outside but now it is flushed out through the bottom outlet of the module (see
Figure 24), ensuring the entire length of fibers have been cleaned. The backwash pump is
not stopped in the transition between Backwash Top and Backwash Bottom. The valves
must be sequenced to prevent damaging the membranes. Similarly to the Backwash Top
step, the duration of the Backwash Bottom is typically 30 45 seconds and optionally
chlorine might be added to help remove foulants or inhibit microbiological activity. The
backwash steps can be repeated numerous times depending on the degree of fouling.
Monitoring the backwash wastewater quality can be useful to optimize the durations of
these steps.

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Figure 24. Backwash Bottom Step for DOW™ Ultrafiltration Modules

5. 6. Forward Flush

The backwash sequence finalizes with a Forward Flush. In this step, feed water is used to
rinse the system to remove remaining solids and the air that might have got trapped in
the system during the precedent steps. Water flows on the outside of the fibers (feed
side) with the filtrate valve closed, and exits through the module top outlet, as shown in
Figure 25. This step typically lasts 30 – 60 seconds or long enough to refill the modules
and purge air and water from the outlet. After this, the systems returns to Filtration mode
and the cycle starts again.

Figure 25. Forward Flush Step for DOW™ Ultrafiltration Modules

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6. DOW™ ULTRAFILTRATION CLEANING

6. 1. Membrane Fouling

Fouling in UF process is understood as the phenomenon that leads to a gradual increase

in the transmembrane pressure (TMP) for a constant product flow (or vice versa, a
decrease in the filtrate flow at a constant feed pressure), typically caused by deposition or
adsorption of the contaminants present in the feed stream on the membrane surface or in
the inner structure.

Occasionally, fouling of the membrane surface occurs and is caused by:

• Inadequate pretreatment
• Overdosing of upstream process coagulants
• Improper materials selection (pumps, piping, etc.)
• Failure of chemical dosing systems
• Inadequate backwash and unsuitable shutdown
• Improper operational control
• Slow build-up of precipitates over extended periods
• Change in feed water composition
• Biological contamination of the feed or filtrate water
• Oil & inorganic contamination of the feed water

From the point of view of the fouling mechanism, there are basically three categories for
fouling, being cake formation, pore adsorption and pore blocking.

Cake Formation normally occurs when the contaminants are too large to enter the
membrane pores, so they deposit on the membrane surface and create an additional
resistance to the passage of water, resulting in a TMP increase.

Pore Adsorption typically happens when the contaminants are smaller than the
membrane pore size, so they deposit on the internal walls of the pores, hence reducing
the diameter of the pores and therefore providing also an additional resistance to the
flow.

Finally, Pore Blocking takes place when the contaminants are of similar size to the
membranes pores, so that blocking occurs and therefore the number of actual pores is
reduced, providing also an additional resistance to the flow.

According to the nature of the contaminants, the fouling can also be categorized as
follows:

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Particulate: This type of fouling is caused by organic and inorganic particles, suspended
solids, colloids and turbidity present in the feed, which are not in dissolved form, and
typically larger than the pore size. This can be reduced by operations upstream the UF
system such us coagulation, sedimentation, clarification or media filtration. The common
cleaning method for this type of fouling is air scour and backwash.

Biological fouling: This is caused by the attachment and growth of microorganisms on

the membranes, which can also lead to the formation of a viscous biofilm. This can be
reduced by using in-line chemical feed of chlorine or biocide or by elimination of
nutrients by using adsorption (e.g., powdered or granular activated carbon, PAC or GAC),
or coagulation upstream the UF system. The common cleaning method for removal of
biological fouling is cleaning with oxidizers or biocides (e.g., Cl2, H2O2, SBS). Note PAC is
available in different grades and can damage the membranes. If using PAC consult with
Dow TS&D.

Inorganic fouling: This is caused by the precipitation of inorganics on the membrane

(e.g., Ca, Mg, Fe, Mn), and can be reduced by using oxidation/precipitation and filtration
as pretreatment to the UF or in some cases using low hardness water for the alkali
chemically enhanced backwash. The common cleaning method for removal of inorganic
fouling is chemically enhanced backwash with acid at pH 2 (e.g., HCl, H2SO4, Citric, or
Oxalic Acid).

Organic fouling: This is the one of the major causes of fouling in the UF processes and is
caused by organics adsorbing on the membrane (silt, organic acids, humic substances), as
the majority of these substances are too small to be retained by the membrane and hence
go through. This can be reduced by using PAC, GAC, or coagulation upstream the UF
system. The common cleaning method for removal of organic fouling is cleaning regimes
with alkali at pH 12 (e.g., NaOH).

Table 9 shows a summary of the fouling types and methods of control.

Table 9. Summary of the fouling types and methods of control

Fouling Type Cause Prevention Cleaning Method

Particles SS, Colloids, Turbidity Coagulation, Clarifiers… Air Scour / Backwash
Bacteriological Control (e.g.,
Cl2 in line). CEB/CIP with
Biological Microorganisms growth
Elimination of nutrients ozidizers/biocides
(PAC, GAC, Coagulation,…)
Oxidation/Precipitation +
CEB/CIP Acid @ pH ~ 2 (e.g.,
Inorganic precipitation Filtration.
Inorganic HCl, H2SO4, Citric Acid, Oxalic
(e.g., Fe, Mn, Ca) Use low hardness water for
Acid…)
CEB Alkali.
Organics adsorption
CEB/CIP Alkali @ pH ~ 11 –
Organic (silt, organic acids, Coagulation, PAC, GAC,…
12 (e.g., NaOH)
humic substances,…)

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6. 2. Chemically Enhanced Backwash (CEB)

CEB operation refers to a Chemically Enhanced Backwash, where chemicals (e.g.,

chlorine, acid or base) are added in the Backwash stream in order to increase the
cleaning effectiveness. The type of chemical used depends on the foulant (refer to Table 9
above), which might be a combination of different ones or change seasonally. The
frequency of a CEB is dependent on the feed water quality, but typically is once per day to
once per week. For high quality feed waters it may not be required.

The CEB process is typically programmed to occur automatically at a preset frequency

but this can be field adjusted after gaining site specific operating experience.
Alternatively it can be initiated based on a TMP set point. The CEB is performed using UF
filtrate.

The CEB is performed following the same steps of a normal backwash sequence except a
soak step is added after the addition of the chemicals, for 5 – 20 minutes, to allow time for
the chemicals to react with contaminants that have attached to the membrane surface or
penetrated the fiber wall. It is recommended however to invert the order of the backwash
steps, i.e., backwash bottom first and then backwash top as the second step, to make sure
that the system remains filled with the chemical solution during the soaking time.
Intermittent air scour (e.g., 5 – 10 seconds every 5 minutes) can be applied as well during
the soak step to increase effectiveness.

After the soak a routine backwash including air scour, gravity drain, top and bottom
backwash, and forward flush is performed to remove any remaining particulates and
purge residual chemicals. After a CEB and at the start of the operating step, the initial
filtrate produced might need to be sent to waste to remove residual chemicals. This step
is dependent on the system piping and valve design and the downstream requirements
for the filtrate. In addition, the CEB can be performed at reduced flux than that used for
standard backwash (e.g., 80 LMH).

6. 3. Cleaning In Place (CIP)

6.3.1. Introduction

The fouling of membrane surfaces results in the gradual performance decline of the UF
System in terms of high operating transmembrane pressure , lower sustainable filtrate
flow or flux, and/or high chemical and power consumption.
Clean-in-Place (CIP) may be accomplished effectively due to the excellent physical
properties and chemical tolerances of the DOW™ Ultrafiltration Hydrophilic-
Polyvinyldifluoride (H-PVDF) membrane material and module components, which are
compatible and resistant to elevated levels of pH, chlorine oxidants, and temperature.
Concentration, cleaning time, temperature, intermittent air scour, and hydraulic
conditions during the cleaning process are important considerations which will affect
cleaning efficiency.

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UF system performance should be monitored on a regular and frequent basis. If cleaning

is delayed too long, fouling may become irreversible and result in potential physical
damage to the UF module or appurtenance equipment. The DOW™ Ultrafiltration
Normalization Tool may be used to analyze UF system performance on a normalized
basis, to remove or minimize the effects of temperature, pressure, and flow so that the
user may differentiate between normal phenomena and real performance upsets due to
fouling. The DOW™ Ultrafiltration Normalization Tool is available from your local
DW&PS Technical Service.
CIP is most effective if it is tailored to remove the specific fouling problem. Sometimes a
wrong choice of cleaning chemicals can make a situation worse. Therefore, the type of
foulants on the UF membrane surface should be understood prior to the CIP, so that the
most effective CIP cleaning solution and sequence may be used for the procedure. There
are different ways to accomplish this:
• Analyze feed water quality.

• Review results of previous cleanings.

• Remove and inspect the feed end of the DOW UF module for indication of
contaminants.

• Inspect the waste discharge after air scour in the backwash step for indication of
contaminants. Sample may be visually inspected or analyzed in laboratory.

• Analyze spent SDI filter paper after grab sample SDI-5 test at UF feed water.

• Destructive autopsy if methods above fail to identify the foulant.

6.3.2. Safety Precautions

• When using any chemicals indicated here or in subsequent sections, follow

accepted safety practices. Consult the chemical manufacturer for detailed
information about safety, handling and disposal.

• When preparing cleaning solutions, ensure that all chemicals are dissolved and
well mixed before circulating the solutions through the modules.

• During pumping and recirculation of cleaning solutions, observe maximum

temperature and pH limits. Please refer to Table 10 below.

Table 10. pH and temperature limits during cleaning

Chemical Type pH, Max/Min Temp., Max

Alkaline Solution 12, Max. 35°C (95°F)
Acid Solution 2, Min. 35°C (95°F)

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6.3.3. CIP Requirements

During regular operation, the surface of the fibers of the UF modules may become fouled
by particles, biological matter, colloidal particles and/or insoluble organic constituents.
Deposits build up on the fiber surfaces during operation, until they result in an increase
of TMP to levels or a decrease of normalized filtrate flow that cannot be recovered on
sustainable basis by regular backwash and CEBs.

DOW™ Ultrafiltration Modules should be cleaned to restore membrane permeability,

when one or more of the below parameters are encountered during regular operation,
after a CEB event. Permeability is the flux, per unit of transmembrane driving force, and
is expressed as LMH/bar or gfd/psi.

• Normalized Permeability drops by 50%

• Normalized TMP increases by 1 bar (14.5 psig) from initial TMP

• Operating TMP reaches a maximum 2.1 bar (30.5 psig)

• In the event that you do not normalize your operating data, please use the above
values for general indication of when to initiate a cleaning event

If delayed too long, the membrane fouling may become irreversible, where cleaning may
not restore membrane permeability. Heavily fouled membranes are more challenging to
clean as it becomes more difficult for the cleaning chemical to penetrate the membrane
surface, and flushing the foulants out of the membranes. Furthermore, the time between
cleanings may become more frequent as the membranes which are not completely
cleaned foul or scale more rapidly.

6.3.4. CIP Equipment

The equipment for CIP is shown in the CIP system flow diagram below (Figure 26). The
materials of construction for selected equipment and ancillaries of the CIP system should
be compatible with the pH, chemical types and concentrations, and temperature of the
CIP solutions.

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Figure 26. CIP System Flow Diagram

CIP TANK Chemical Mixing Tank Polyethylene, Polypropylene or FRP

CIP PUMP Low-Pressure Pump 316SS, or non-metallic composite
CIP Cartridge Filter Polypropylene, 5 or10 micron PVC, FRP, or SS housing
HT CIP Tank Heater (Optional)
TIT Temperature Transmitter
LIT Level Transmitter
LG Level Gauge
PG Pressure Gauge
FIT Flow Transmitter
AIT pH Analyzer

1) The CIP Tank may be constructed of polyethylene (PE), polypropylene (PP), or

fiberglass-reinforced plastic (FRP). The tank should be provided with a removable
cover and a temperature gauge/transmitter. The cleaning procedure is more
effective when performed at an elevated temperature. The chemical solution
should be maintained in accordance to the pH and temperature guidelines listed in
Table 1. It is recommended to not use a cleaning temperature below 15°C (59°F),
because of the slower chemical kinetics at low temperatures. Cooling after a
heated CIP may also be required in certain geographic regions.

A general rule of thumb used in sizing of the CIP Tank is to use the approximate
volume of all of the UF modules, and add the hold-up volume in the feed and
return lines, within the boundaries of the UF system to be cleaned in one CIP event
plus enough volume to maintain a Net Positive Suction Head (NPSH) for the CIP
pump.

For example, to clean a DOW™ Ultrafiltration system containing ten (10) nos. of
DOW™ SFD / SFP–2880 modules, to be cleaned in one CIP event, the following
calculations may be considered:

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A. Volume in UF Modules
Vmodule = 39 L (10.3 gal) / module
V10 modules = 0.039 m3 x 10 = 0.39 m3 (103.03 gal)

B. Volume in Pipes
(assume 10 m (32.8 ft) length of DN50 PN10 (2-in. SCH 80) UPVC pipe)
Vpipe  r 2 l ; where r = radius; l = length
Vpipe = 3.14 x (0.025 m)2 x 10 m
Vpipe = 0.0196 m3 (5.18 gal)

C. Volume in UF Modules and Pipes (or, CIP Tank Volume)

V10 modules + pipe = 0.39 m3+ 0.0196 m3= 0.41 m3 (108.2 gal)

Therefore, the CIP tank should be minimum 0.41 m3 (108.2 gal).

2) The CIP Pump should be sized for the flows and pressures given in Table 11,
making allowances for pressure loss in the piping and across the CIP cartridge
filter.

Table 11. Recommended CIP Feed Flowrate per UF module

DOWTM Ultrafiltration Product Feed Flowrate (per UF module) Feed Pressure (at UF module)
m3/h gpm bar psig
SFP/SFP-2660 1.0 4.4 < 3.0 < 43.5
SFD/SFP-2860(XP); IP(D)-51(XP) 1.5 6.6 < 3.0 < 43.5
SFD/SFP-2880(XP); IP(D)-77(XP) 1.5 6.6 < 3.0 < 43.5

3) Appropriate valves, flow meters and pressure gauges should be installed to

adequately control the flow. Service lines may be either hard-piped or use flexible
hoses. In either case, the flow velocity should be maintained at 3 m/s (10 ft/s) or
less.

4) Ensure that the CIP concentrate and filtrate return lines are submerged in the CIP
Tank to minimize foaming.

6.3.5. CIP Procedure

The cleaning duration for each CIP solution is expected to require about 6 hours,
depending on target recycle and soak durations, and actual time required to prepare
chemicals and equipment. The permeability of the UF membranes to be cleaned should
be measured with online instrumentation for before and after the CIP with each type of
solution, to allow for baseline and assessment of chemical cleaning efficiency and
indication of the type of fouling. Permeability (LMH/bar, or gfd/psi) may be measured on

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normalized terms using the DOW™ Ultrafiltration Normalization Tool, or on approximate

basis using field measured values of flow and pressure at the feed and filtrate.
Table 12 provides a general valve sequence table for the steps of the CIP procedure. A
description of each step of the CIP procedure follows in this section.

Table 12. General Valve Sequence Table for CIP Procedure

CIP Outlet Valve (Concentrate)

CIP Outlet Valve (Filtrate)

UF Forward Flush Valve

CIP Inlet Valve (Feed)

UF Backwash Pump
Step

CIP Recycle Valve

CIP Step 1

CIP Tank Heater

No.

UF Feed Pump

CIP Pump
1 Install CIP Cartridge Filter Elements O X X X X X X X X
2 Make-up Cleaning Solution O X X O O X X X O
3 Regular Backwash, Pre-CIP X O O O O X X X O
4 Remove from Service X X X O O X X X O
5 Drain X X X O O X X X O
6 Low-flow Pumping X X X O O O O X O
7 Recycle X X X O O O O O O
8 Soak2 X X O3 X X X X X X
9 Final Recycle X X X O O O O O O
10 Flush Out X X X O X O O O O
11 Regular Backwash, Post-CIP X O O X X X X X X
12 Return to Service O X X X X X X X X
Notes:
X – Valve Closed, or Equipment Off
O – Valve Open, or Equipment On
1 Valve positions and equipment status are dependent on the previous step in the sequence. For example, during

Regular Backwash, Pre-CIP (Step 3) the CIP Pump is not required to be On in the stand-alone step, however the CIP
Pump continues to be On to allow for mixing of cleaning solution (Step 2) which occurs in-parallel.
2 Valve sequence will differ if low-flow recirculation is practiced during extended soak duration. Refer to Section 6.2.6,

CIP Tips.
3 If intermittent air scour is practiced during Soak step, the Forward Flush Valve should be opened to allow venting of

air introduced into UF modules. Elevation of system piping will help prevent drain out of CIP solution during this
process.

1) Install CIP cartridge filter elements (5 or 10 µm rating).

2) Make up cleaning solution. Preheat cleaning solution to desired temperature, and

meanwhile, open the CIP recycle valve to mix the solution with pump and/or agitator.
For seawater applications, RO permeate is preferred for the UF CIP make-up solution;
however, potable water or UF filtrate may be used if there is no alternative water
source. Always add the chemical to the CIP make up water to avoid exothermic
reactions.

3) Regular backwash, pre-CIP. Conduct a regular backwash of the UF skid to remove

loose contaminants prior to the CIP.

4) Remove from Service. Remove the UF skid to be cleaned from service by normal

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shutdown procedures. Ensure manual and actuated valves are in correct position
prior to the CIP.

5) Drain out water in the UF skid. Residual water in UF skid will dilute the
concentration of cleaning solution. Therefore, drain the residual water by opening the
forward flush outlet valve and backwash outlet valve, and close when the UF skids
are drained of standing water.

6) Low-flow pumping. After the UF skid is drained of residual water, activate the CIP
pump. Pump mixed, pre-heated cleaning solution through the feed side of the UF
modules (i.e., filtrate valve closed) at conditions of low flowrate (about half of that
shown in Table 11) and low pressure to displace remaining standing water and solids
in the UF modules and rack.

7) Recycle. Recycle the cleaning solution at the flowrates shown in Table 11. CIP
solution continues to be introduced into the UF modules from the feed side. Continue
to recycle and allow the temperature to stabilize. Measure the pH of the solution and
adjust the pH, if needed – e.g., if pH falls or increases by greater than 1 pH unit from
target level. If NaOCl is included in the CIP solution, the recycled solution may also be
measured for free chlorine using a portable colorimeter, where NaOCl chemical is
replenished if the measured chlorine falls below 75% of target concentration. The
recycle step typically lasts 1 hour, depending on extent of fouling. Initially, recycle
only through the feed side of the module (i.e., filtrate valve closed) so that the solids
accumulated on the membrane surface are flushed out of the system and not pushed
back again into the membrane; after 15 – 20 minutes open as well the filtrate valve
(while the concentrate/reject valve remains partially open) so that the chemical
solution also flows through the fiber and filtrate piping back to the CIP tank (target
10 – 20% filtrate and 80 – 90% concentrate returns).

8) Soak. Deactivate the CIP Pump and CIP Tank Heater. Close the CIP inlet, outlet and
return valves, and allow the modules to soak. The soak step is typically 2 hours,
depending on extent of fouling; sometimes, an overnight soak of 10 – 15 hours is
effective for recovery of severe fouling. To maintain a high temperature and to
improve cleaning efficiency during an extended soak period, use a slow recirculation
rate (about 10% of that shown in Table 11). We recommend intermittent air scour
for e.g., 5 minutes, each 30 minutes of the soak period to agitate fibers for enhanced
cleaning benefits; if intermittent air scour is practiced during soak step, the Forward
Flush Valve should be opened to allow venting of air introduced into UF modules.

9) Final Recycle. Recycle the cleaning solution at the flowrates shown in Table 11. CIP
solution is again introduced into the UF modules from the feed side. The final recycle
step typically lasts 20 – 30 minutes duration.

10) Flush out. After the final recycle period, drain the modules and drain the CIP Tank.
Fill the tank with RO permeate (preferred, for seawater applications), potable water,
or UF filtrate to prepare for the Flush out step. RO permeate is preferred for
seawater applications, to prevent reaction of impurities in the flush-out water with
the remaining cleaning solution. Perform the Flush out of the CIP tank and piping by
repeat of Low-flow pumping (Step 6), and Recycle (Step 7) for a period of 10 minutes.
A plan for discharge of the chemical wastes in accordance to local regulations should
be developed prior to performing the CIP.

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11) Regular backwash, post-CIP. Conduct a regular backwash of the UF skid to prepare
the system for return to service.

12) Return to Service.

6.3.6. CIP Tips

1) The fouling of membrane modules typically consists of a combination of fouling

mechanisms, e.g., a mixture of organic fouling, colloidal fouling and biofouling, which
often requires a two-step cleaning program: alkaline cleaning followed by acid
cleaning. We recommend alkaline cleaning as the first cleaning step. Acid cleaning
should only be applied as the first cleaning step if it is known that only calcium
carbonate or iron hydroxide is present on the membrane surface. Acid cleaners
typically react with silica, organics (e.g., humic acids), and biofilm present on the
membrane surface, which may cause further decline of membrane performance if
being introduced first.

2) Always measure the pH during cleaning. If the pH increases more than 1 pH units
during acid cleaning, more acid needs to be added. If the pH decreases more than 1
pH units during alkaline cleaning, more caustic needs to be added.

3) Inspect the appearance of the spent CIP solution at various points during the recycle
and soak steps. The visual appearance sometimes provides indication of the type of
fouling, especially in the case of inorganic metals.

4) Long soak times. It is possible for the chemical cleaning solution to be fully saturated,
which allows the foulants to precipitate back onto the fiber surface. In addition, the
temperature will drop during this period; therefore the soaking becomes less
effective. It is recommended to circulate the solution regularly in order to maintain
the temperature (temperature should not drop more than 5°C/41°F) and add
chemicals if the pH needs to be adjusted.

5) Fresh cleaning solution needs to be prepared when the cleaning solution becomes
turbid and/or discolored. The cleaning is repeated with a fresh cleaning solution.

6) Intermittent air scour immediately before the CIP (prior to Step 5, Drain out water in
UF skid), during, and just at the end of the soaking step (Step 8, Soak), can benefit the
cleaning effectiveness in more challenging cases. It might occur that due to the
aeration and depending on the system piping layout, some of the chemical solution
volume is lost through the module top port; in this case the system must be refilled
again with chemical solution using the CIP pump.

7) Thermal Shock should be considered in cold water environments, to prevent damage

to UF modules and piping systems in cases where high-temperature CIP solution is
introduced into low-temperature system (e.g., Step 6, Low-flow Pumping), or low-
temperature flush water is introduced into a warm or heated system (e.g., Step 10,
Flush Out). In this case it is recommended to recirculate the solution while it is being
heated-up up for a gradual temperature increase. Similarly, at the end of the cleaning,
it is recommended to let the system cool down before flushing it out (Step 10 of
previous section) with cold water.

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8) Use the least harsh cleaning solution possible, including cleaning parameters of pH,
temperature, and solution strength.

6.3.7. CIP Chemicals

Table 13 lists general cleaning chemicals that are effective to recover membrane
permeability in most situations. Generic acid cleaners and alkaline cleaners are standard,
widely available cleaning chemicals. Acid cleaners are used to remove inorganic
precipitates (e.g., including iron), while alkaline cleaners are used to remove organic
fouling (e.g., biological matter). Specialty cleaning chemicals may be used in cases of
severe fouling, or unique cleaning requirements. For seawater applications, RO permeate
is preferred for the UF CIP make-up solution; in cases when RO permeate is not available,
please discuss project-specific conditions of water quality with DW&PS Technical Service
to evaluate if potable water or UF filtrate may be used as an alternative water source.
Depending on the make-up solution water source, the feed water may be highly buffered
(i.e, high alkalinity), where additional acid or base chemical may need to be added to
reach the target pH level – which is pH 2 for acid cleans, and pH 12 for alkaline cleans.
Also, a softener can be used on the CIP make up water system to remove hardness.
Table 13. General CIP Cleaning Solutions

Solution 2 Solution 3 Solution 4

Solution 1
Cleaning Solution 2% (W) 2% (W) 0.2% (W) NaOCl +
0.2% (W) HCl,
Citric Acid at Oxalic Acid 0.1% (W) NaOH, at
at pH 2, 35°C
Targeted Foulants pH 2, 35°C at pH 2, 35°C pH 11.5, 35°C
(95°F) max.
(95°F) max. (95°F) max. (95°F) max.
Inorganic Preferred Alternative Alternative
Particulate / Colloidal Preferred Alternative Alternative Preferred
Microbial / Biological Preferred
Organic Preferred
Combined Metals and
Preferred Alternative
Organic Complexes
Notes:
1. (W) denotes weight percent of active ingredient.
2. Solution 2 (Citric Acid) should be thoroughly flushed from system before return to service due to
organics loading.

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7. HANDLING AND STORAGE PROCEDURES FOR DOW™

ULTRAFILTRATION MODULES

This chapter provides general information for the handling and storage of DOW™
Ultrafiltration Modules. The information in this bulletin applies to the DOW™
Ultrafiltration products including SFD / SFP-2660, -2860, and -2880, IntegraPac™ IP/
IPD-77, -51(XP), and IntegraFlux™ SFP/D -2860/80XP.
Dow Water and Process Solutions (DW&PS) recommends that the procedures for DOW™
Ultrafiltration long-term shutdown & storage, in particular, be closely coordinated with
local DW&PS technical service to facilitate a positive experience, and to train facility
operations & engineering staff.

7. 1. General

DOW™ Ultrafiltration modules should be handled in such a way to help control the spread
of and reduce bio-growth during long-term storage, shipping or system shutdowns.
DW&PS recommends that the modules be shipped and stored in their original factory
packaging, and loaded into the system skids just prior to start-up. There are cases when
the customer may prefer to install the modules onto the skids with significant time before
start-up and commissioning; storage guidelines for these cases are also addressed in this
chapter. If the module is exposed to air for an extended period of time, the membrane
may become dry and at risk to irreversible damage; therefore, it is important to keep the
membrane wetted.

7.1.1 Safety Precautions

• When using any chemicals indicated here or in subsequent sections, follow

accepted safety practices. Consult the chemical manufacturer for detailed
information about safety, handling, and disposal.
• When preparing solutions, ensure that all chemicals are dissolved and well mixed
before introduction into the modules.

• Wear protective eyewear and respirator when handling sodium metabisulfite

(SMBS) and storage solution.
• Wear protective gloves and sleeves to avoid prolonged contact with SMBS and
storage solution.
• Consult the relevant Safety Data Sheets (SDS), as supplied by the manufacturer of
the chemicals.

7. 2. Factory Storage & Shipping of DOW™ Ultrafiltration Modules

As part of the quality assurance program, all DOW™ Ultrafiltration modules are tested for
integrity and performance (“wet tested”) at the factory, prior to packaging and shipment.
To control dehydration and biological growth, DOW™ Ultrafiltration modules are shipped

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wetted and preserved in a non-hazardous standard storage solution containing pH

buffered 1 wt% food-grade SMBS. The storage solution inhibits biological growth during
storage and shipping of the modules. SDS for these chemicals are available from DW&PS.
Preservative solution is automatically delivered into the module housings prior to sealing
of the module’s feed and outlet ports by blinds at the grooved couplings and plug at the
threaded air connection. The approximate volume of standard storage solution used at
shipping for each module is 2 L (0.5 gal) for SFD / SFP-2660; 4 L (1 gal) for SFD / SFP-
2860(XP), and IP / IPD-51(XP); and 6 L (1.6 gal) for SFD / SFP-2880(XP), and IP / IPD-
77(XP). If glycerin is added for freeze protection the holdup module volume will be used.
After adding preservative and sealing the openings, the modules are wrapped in plastic
bags prior to boxing for dust protection. Precise solution volume and good sealing of the
couplings help ensure a stable preservative environment during transportation and
storage of new modules.
The wrapped modules are stored in cardboard boxes, with one module per box. A small
box containing installation parts is inserted into each cardboard box shipped. Saddle-
shaped cushion inserts are located at both ends and along the module to support and
protect the modules from damage during shipping and handling. The modules are stored
in the horizontal position, with the sealed port connections facing upwards. Labels to
identify the port locations and position the boxes are provided on the exterior of the
packaging to allow proper storage. To prevent collapse of the boxed modules, stacking is
limited to four layers for all SFD / SFP, IntegraPac™, IntegraFlux™ products. Depending
on the total number of modules and required shipping method, the boxed modules are
either palleted or crated for transportation.
Modules must be protected from freezing or excessive heat during shipping and storage.
The temperature limits for modules during standard shipping and storage are 1°C
(33.8°F) to 40°C (104°F). Avoid abrupt variations in temperature; equalization should be
allowed to occur at a maximum temperature differential of ± 1°C (1.8°F) per minute.
Irreversible damage to the membrane and damage of the module components may result
if the modules are exposed to temperatures outside these limits. If freezing conditions are
anticipated during the customer’s shipping and storage of modules, please notify DW&PS
at the time of order placement. Glycerine can be added to the storage solution by DW&PS
at the factory prior to shipping to protect the modules under freezing conditions.

Mechanical damage to module housing, membrane, and connections may result if the
module, boxed module, pallet, or crate is dropped, and otherwise mis-handled. The
modules should be handled with care, with particular attention during transportation.

7. 3. Storage of New DOW™ Ultrafiltration Modules

Modules are recommended to be shipped and stored in their original packaging separate
from the system skids, and loaded into the system just prior to start-up. There may be
cases where the customer prefers to pre-install the modules on the system skids; for
example, to allow factory acceptance testing of packaged or mobile systems prior to
shipping, or work scheduling at site to eliminate the separate step for module loading. In
cases where pre-installation of modules onto the system skids are preferred for
alignment of process/mechanical piping, frame and supports, blank or “dummy” modules

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are available from DW&PS to assist in alignment and shipping of system skids from the
customer’s facility to the project site. It is recommended that seals and plugs for isolation
and storage solution containment be saved for future use.
These guidelines should be followed for storage of new DOW™ Ultrafiltration modules:

• Keep modules in original factory packaging. There are cases when the customer
may prefer to load the modules onto the skids with prior to start-up &
commissioning; guidelines for storage of modules installed on-skid are provided in
the Sections 7.4 and 7.5, Short-Term and Long-Term Shutdown & Storage of Used
DOW™ Ultrafiltration Modules.
• To minimize the potential for leakage of preservative, modules should be stored in
horizontal position, with the sealed port connections facing upwards. Labels of the
port locations are provided on the exterior of the box to facilitate storage. If
leakage is observed, please refer to guidelines for replenishment of storage
solution provided in the Sections 7.4 and 7.5, Short-Term and Long-Term
Shutdown & Storage of Used DOW™ Ultrafiltration Modules.
• To prevent collapse of the boxed modules, limit vertical stacking to four layers for
all SFD/SFP, IntegraPac™ and IntegraFlux™ modules.
• Store inside a cool and dry building or warehouse, away from sources of heat,
ignition, and direct sunlight. An ambient temperature of 20°C (68°F) to 35°C
(95°F) is recommended for ideal storage conditions.
• Temperature limits for modules during shipping and storage is 1°C (33.8°F) to
40°C (104°F). Modules must be protected from freezing or excessive heat during
shipping and storage. Avoid abrupt variations in temperature; equalization should
be allowed to occur at a maximum temperature differential of ± 1°C (1.8°F) per
minute. If freezing conditions are anticipated during the customer’s shipping and
storage of modules, please notify DW&PS at the time of order placement. Glycerin
may be added to the storage solution by DW&PS at the factory prior to shipping to
allow for shipment and storage at freezing conditions.
• Sealed modules may be stored up to 1 year from date of manufacture, at the
recommended storage conditions in the original packaging, without additional
measures required for storage. If storage exceeds 1 year from date of manufacture,
guidelines for confirmation and replenishment of storage are provided in Section
7.5, Long-Term Shutdown & Storage of Used DOW™ Ultrafiltration Modules.

7. 4. Short-Term Shutdown & Storage of Used DOW™ Ultrafiltration

Modules

This section provides guidelines for the short-term shutdown & storage of used (installed
and operated) DOW™ Ultrafiltration modules, and addresses cases where the modules
are either (a) stored off-skid as individual modules, or (b) stored on-skid. Short-term is
considered as periods where the modules have been drained or used in-service, and will
remain out of operation for less than 4 days.

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Note that the quantities of storage solution required for on-skid storage is greater than
for off-skid storage to allow for complete wetting of fibers; off-skid storage allows for
horizontal storage which decreases the amount of required solution.
If the modules are expected to be exposed to freezing conditions, glycerin should be
added to the storage solution for either short- or long-term shutdown & storage
conditions. Refer to Section 7.6, Freeze-Protection of Used DOW™ Ultrafiltration Modules.

7.4.1 Short-Term Shutdown & Storage, Off-Skid Storage

For cases of short-term shutdown & storage, where the modules will be stored off-skid,
and the modules will be placed in service within the next 4 days, SMBS storage solution is
not required. Clean water alone is sufficient to keep the fibers in wetted condition to
avoid dehydration. Clean water sources may be from potable water or RO permeate. The
approximate volume of water required for each module is 16 L (4 gal) for SFD/SFP-2660;
35 L (9 gal) for SFD/SFP-2860(XP); 39 L (10 gal) for SFD/SFP-2880(XP); 49 L (13 gal) for
IP/IPD-51(XP) and 53 L (14 gal) for IP/IPD-77(XP). These quantities of water allow for
near to complete fill of the module with water.

If the modules have been in-service, a normal system chemical enhanced backwash (CEB)
of alkaline, followed by acid, should be conducted before removal of the modules for
short-term shutdown & storage. If CEB facilities are not available, then a normal
backwash consisting of water and air scour steps should be conducted prior to removal of
modules off the skid.
Once the modules are removed water may be fed into the module through the feed port
by gravity or low-rate pumping. The module should be kept in horizontal position at time
of fill, with the far side filtrate and concentrate ports sealed by blind disc at the grooved
couplings. Once the water is added into the module, all service port connections should
be sealed tightly using the original blind discs and plugs to retain the solution inside the
module. If these parts have not been retained an isolation package can be ordered from
the DOW™ Ultrafiltration Module Spare Parts List. To minimize the potential for leakage
of preservative, modules should be stored in the horizontal position, with the sealed port
connections facing upwards. Modules may be kept in the original cardboard boxes. Labels
of the port locations are provided on the exterior of the box to facilitate storage.

7.4.2 Short-Term Shutdown & Storage, On-Skid Storage

For cases of short-term shutdown & storage, where the modules will be stored on the
skid, and the modules will be placed in service within the next 4 days, clean water alone is
sufficient to keep the fibers in wetted condition to avoid dehydration. As for off-rack
storage, clean water sources from potable water or RO permeate should be used. The
approximate volume of water required for each module is 16 L (4 gal) for SFD/SFP-2660;
35 L (9 gal) for SFD/SFP-2860(XP); 39 L (10 gal) for SFD/SFP-2880(XP); 49 L (13 gal) for
IP/IPD-51(XP) and 53 L (14 gal) for IP/IPD-77(XP). These quantities of water allow for
near to complete fill of the module with water.
If the modules have been in-service, a normal system CEB of alkaline, followed by acid,
should be conducted on the modules before short-term shutdown & storage. If CEB
facilities are not available, then a normal backwash consisting of water and air scour
steps should be initiated prior to short-term shutdown & storage.

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DW&PS recommends that the UF CIP system be used for delivery of the water into the
modules from the feed side. Refer to section 6.2.5 in this document for general procedure.

7. 5. Long-Term Shutdown & Storage of Used DOW™ Ultrafiltration

Modules

This section provides guidelines for the long-term shutdown & storage of used DOW™
Ultrafiltration modules, and addresses cases where the modules are either (a) stored off-
skid as individual modules, or (b) stored on-skid. Long-term is considered as periods
where the modules have been drained or used in-service, and will remain out of
operation for more than 4 days.
Note that the quantities of storage solution required for on-skid storage is greater than
for off-skid storage to allow for complete wetting of fibers; off-skid storage allows for
horizontal storage which decreases the amount of required solution.
Re-preserved elements should be visually inspected for biological growth every three
months. If the storage solution is not clear, the module should be re-preserved and re-
packed as described above. Contact of the SMBS solution with air / oxygen will oxidize
bisulfite to sulfuric acid. Therefore, the pH of the solution should be spot checked on
random modules every 3 months. Re-storage is required when the measured pH is 3 or
lower. For medium to large orders, to avoid inspection of every module, a representative
sampling of the total number of modules (e.g., 5%) may be inspected for visual
appearance and pH.
If the modules are expected to be exposed to freezing conditions, glycerin should be
added to the storage solution for either short- or long-term shutdown & storage
conditions. Refer to Section 7.6, Freeze-Protection of Used DOW™ Ultrafiltration Modules.

7.5.1 Long-Term Shutdown & Storage, Off-Skid Storage

For cases of long-term shutdown & storage, where the modules will be stored off-skid,
and the modules will remain out-of-service for more than 4 days, a storage solution
containing pH buffered 1 wt% food-grade SMBS is required to effectively minimize
biological growth in the modules during the storage period.
If the modules have been in-service, a normal system CEB and CIP should be conducted
on the modules before removal of the modules for long-term shutdown & storage. Refer
to Section 6.2.5 in this document for CIP Procedure. If CEB and/or CIP facilities are not
available, then a normal backwash consisting of water and air scour steps should be
initiated prior to removal of modules off the skid.
The approximate volume of storage solution required for each module is 2 L (0.5 gal) for
SFD / SFP-2660; 4 L (1 gal) for SFD / SFP-2860(XP), and IP / IPD-51(XP); and 6 L
(1.6 gal) for SFD / SFP-2880(XP), and IP / IPD-77(XP). For every liter of solution
required, 12 grams of food-grade SMBS are added for biostat, and 8 grams of sodium
hydroxide and 27 grams of citric acid for pH buffer. Scale-up the preservative formulation
to prepare the required volumes of storage solution for number and type of modules to
be preserved.

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The storage solution may be fed into the module through the feed port by gravity or low-
rate pumping. The module should be kept in horizontal position at time of fill, with the far
side filtrate and concentrate ports sealed by blind disc at the grooved couplings. Once the
target volume of storage solution is added into the module, all service port connections
should be sealed tightly using the original blind discs and plugs to retain the solution
inside the module. To minimize the potential for leakage of preservative, modules should
be stored in horizontal position, with the blanked port connections facing upwards.
Modules may be kept in the original cardboard boxes. Labels of the port locations are
provided on the exterior of the box to facilitate storage.

7.5.2 Long-Term Shutdown & Storage, On-Skid Storage

For cases of long-term shutdown & storage, where the modules will be stored on the skid,
and the modules will remain out-of-service for more than 4 days, a storage solution
containing pH buffered 1 wt% food-grade SMBS is required to effectively minimize
biological growth in the modules during the storage period.
Similar to off-skid storage, if the modules have been in-service, a normal system CEB and
CIP should be conducted before removal of the modules for long-term shutdown &
storage. If CEB and/or CIP facilities are not available, then a normal backwash consisting
of water and air scour steps should be initiated prior to removal of modules off the skid.
The approximate volume of storage solution required for each module is 16 L (4 gal) for
SFD/SFP-2660; 35 L (9 gal) for SFD/SFP-2860(XP); 39 L (10 gal) for SFD/SFP-2880(XP);
49 L (13 gal) for IP/IPD-51(XP); and 53 L (14 gal) for IP/IPD-77(XP). These quantities of
solution allow for near to complete fill of the module with water. For every liter of
solution required, 12 grams of food-grade SMBS are added for biostat, and 8 grams of
sodium hydroxide and 27 grams of citric acid for pH buffer. Scale-up as required during
the solution preparation procedure to prepare the required quantities of storage solution
for number and type of modules to be preserved.
DW&PS recommends that the UF CIP system be used for delivery of the storage solution
into the modules from the feed side. Refer to Section 6.2.5 in this document for CIP
general procedure.

7. 6. Freeze-Protection of Used DOWTM Ultrafiltration Modules

Modules must be protected from freezing during storage. The temperature limits for
modules during storage is 1°C (33.8°F), minimum. Irreversible damage to the membrane
and damage of the module components may result if the modules are exposed to
temperatures below this limit.
If the modules are expected to be exposed to freezing conditions, glycerin should be
added to the storage solution for either short- or long-term shutdown & storage
conditions. For cases when freezing is expected and notified to DW&PS, glycerin is added
to the storage solution by DW&PS at the factory prior to shipping to allow for shipment
and storage at freezing conditions. For re-storage by customer, food-grade glycerin
should be applied to the storage solution, at the target strengths detailed in Table 14.

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Table 14. Summary of the target glycerin strengths

Glycerin Freezing Point Freezing Point

Viscosity
(wt%) Depression Depression
(cP)
(°C) (°F)
0.5 1.011 0.07 0.13
3.0 1.074 0.63 1.13
5.0 1.127 1.08 1.94
9.0 1.256 2.06 3.71
12.0 1.365 2.88 5.18
14.0 1.445 3.47 6.25
16.0 1.533 4.09 7.36
20.0 1.737 5.46 9.83
24.0 1.988 7.01 12.62
28.0 2.279 8.77 15.79
32.0 2.637 10.74 19.33
36.0 3.088 12.96 23.33
40.0 3.653 15.50 27.90
44.0 4.443 17.73 31.91
48.0 5.413 20.39 36.70
52.0 6.666 23.22 41.80
56.0 8.349 26.23 47.21
60.0 10.681 29.41 52.94

7. 7. Re-Wetting of Dried Out DOW™ Ultrafiltration Modules

Modules that have dried out membranes due to improper storage may irreversibly lose
water permeability. Re-wetting may be successful with one of the three following
methods:

a) Soak modules in 50/50% ethanol/water or propanol/water for 15 minutes.

b) Pressurize the module with UF feedwater to a target pressure of 4.75 bar

(68.9 psi). The UF feed pump should be of adequate capacity to meet the target
pressure at low flow conditions. During pressurization, slowly close the filtrate
until the target pressure is achieved. Close the feed and filtrate valves for hold at
the target pressure for 30 minutes. Take care that the filtrate port is re-opened
slowly as the feed pressure is released. Do not exceed a transmembrane pressure
(TMP) (pressure drop from feed to filtrate side of the membrane) of 2.1 bar
(30.5 psi). This procedure should be carried out while the modules are installed on
the skid.

c) Soak modules in 1% HCl or 4% HNO3 solution for 24 hours. During fill of the
module, ensure that the module is in a vertical position to allow the escape of
entrapped air.

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8. DOW™ ULTRAFILTRATION MAINTENANCE AND TROUBLESHOOTING

8. 1. Introduction

Proper data record keeping and plant performance normalization are indispensable for
early detection of performance issues in ultrafiltration systems. Adequate instruments
and regular calibration are also critical to ensure accurate readings and anticipate
potential operating issues. This section will cover basic aspects for a proper maintenance
of ultrafiltration systems as well as some troubleshooting tips.

8. 2. Instruments for System Operation

For a proper control and monitoring of the ultrafiltration system, the appropriate
instruments must be put in place. Table 15 below shows the usual instruments required
for the ultrafiltration system (provided by the equipment manufacturer). The data is
typically logged by the plant SCADA system every 1 – 10 seconds.

Table 15. Minimum instruments recommended in an Ultrafiltration system

Parameter Feed Filtrate Backwash CEB CIP Air Scour

Pressure X X X X X X
Flow X X X X X
Temperature X X
pH X X
Turbidity X X

For a detailed Process and Instrumentation Diagram of a typical UF system using

DOW™ UF modules contact Dow.

8. 3. Record Keeping

In order to assess the performance of the Ultrafiltration system, it is important that all
relevant data are manually recorded and collected on a daily basis (ideally once per shift)
for each UF train/rack, independently of the data stored automatically by the plant data
acquisition systems. This allows keeping track of the performance, establishing baseline
performance, and confirmation of the readings of transmitters and gauges. Besides it is a
valuable tool for troubleshooting and warranty claims.

The following list shows the minimum recommended measurements to be taken in an

ultrafiltration system:

• Date and Time.

• Feed Water Temperature.

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• Pre-Screen Inlet and Outlet Pressure.

• UF Feed Water and Filtrate Pressure (and concentrate pressure in case of Cross-
Flow or Bleed-Mode operation). Take measurements before and after events such
as Backwash or Chemical Cleanings in order to evaluate the effectiveness of the
cleanings.
• Backwash interval.
• Filtrate Flow (and Cross-Flow or Bleed-Flow if applicable).
• Feed and Filtrate Turbidity.
• Feed and Filtrate SDI.
• Backwash flow (and calculate flux) and duration (including Air Scour, gravity
drain, backwash top and backwash bottom, and forward flush steps).
• CEB frequency, duration, chemical concentrations used/pH, etc.
• CIP frequency, duration, chemical concentrations used/pH, etc.
• Calibration of all gauges and meters based on manufacturers' recommendations as
to method and frequency.
• Any unusual incidents, for example, pretreatment upsets or feed water excursions,
integrity failures, fiber repairs, shutdowns, etc.

Refer to Chapter 2 for details of the recommended water quality parameters to be

monitored on a regular basis during the operation of the plant.

Examples of data logging sheets are shown in Figures 27 and 28 below.

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DOW™ UF Data Log Sheet

Customer:
System Information: (pretreatment process, chemical feed type and dosages, etc):

UF Module Type: Number of Skids: Number of Membrane Area:

Modules/skid:
Date: Time: Cumulative hours of Recorded By:
operation:
Parameters Unit Recorded Value Comments
Data Collected
Temperature (T) °C or °F
Pre-filter Inlet Pressure psi or bar
Pre-filter Outlet Pressure psi or bar
UF Feed Pressure (Pf) psi or bar
UF Filtrate Pressure (Pp) psi or bar
UF Concentrate Pressure (Pc) psi or bar
UF Filtrate Flow / skid (Qp) gpm or m3/hr
UF Conc. Bleed Flow / skid (Qc) gpm or m3/hr
UF Backwash Flow / skid (Qbw) gpm or m3/hr
UF Forward Flush / skid (Qff) gpm or m3/hr
Filtration time per cycle (tf) minutes
Backwash time per cycle (tbw) seconds
Forward flush time per cycle (tff) seconds
Air Scour time per cycle seconds
CEB Alkali frequency hours
CEB Alkali pH ---
CEB Acid frequency hours
CEB Acid pH ---
UF Feed Turbidity NTU
UF Filtrate Turbidity NTU
UF Feed TSS ppm or mg/L
UF Filtrate TSS ppm or mg/L
UF Filtrate SDI15 %/min
Performance
Gross Flux (J) gfd or lmh
Transmembrane Pressure (TMP) psi or bar
Permeability (LN, 20) gfd/psi or lmh/bar
Equations to Calculate Performance
Transmembrane Pressure (TMP) = Pf - Pp
Recovery (R) = (Qp* tf - Qbw* tbw) / (Qp* tf + Qff * tff) * 100

Figure 27. Example of DOW™ UF Operation Log Sheet

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DOWTM UF CIP Record Sheet

Customer:

System Information: (pretreatment process, chemical feed type and dosages, etc.)

Cumulative
Number of Number of Total number of
UF Module Type: hours of
Skids: Modules/skid: cleaning:
operation:
Cumulative hours of operation after
Date: Time: Recorded By:
last cleaning:
Item Unit First Solution Second Solution Remarks
Pre-cleaning Air Scour and Backwash
Backwash Water Source ---
Backwash Flux LMH or gfd
Nm3/h or
Air flowrate per module
scfm
Cleaning Chemicals
Volume of cleaning solution L or US gal
Acid (also list type used) L or US gal
Caustic soda (%) L or US gal
Sodium hypochlorite (%) L or US gal
Others Chemicals L or US gal
CIP Operating Conditions
Solution concentration %

pH ---

Temperature °C or °F
Circulation flowrate m3/h or gpm
Duration of initial
minutes
circulation
Soaking period minutes
Duration of final circulation minutes
Final Backwash and Flush/Rinse
Source of water ---
Flowrate m3/h or gpm
Duration minutes
pH of waste streams ---

Figure 28. Example of DOW™ UF CIP Log Sheet

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8. 4. Data Normalization

8.4.1. Introduction

The temperature of the feed water affects the permeability of a membrane filtration
system. At lower temperatures water becomes increasingly viscous (approximately 3%
for every Celsius degree); therefore, lower temperatures require increasing the
transmembrane pressure (TMP) to maintain a constant flux or reduce the flux through
the membrane at constant TMP, as the resistance through the membrane increases.
Consequently, this viscosity effect should be considered in the facility design to ensure
adequate production capacity in all scenarios and understand the impact to energy
consumption.

The term “Normalization” is an industry practice for correcting variations that would
otherwise appear as a filtrate flux or TMP change, and lead to misinterpretations of the
membrane process performance (e.g., a decrease in membrane permeability (i.e., flux
divided by TMP) that would mistakenly be interpreted as a result of a fouling
phenomenon, when it is only due to a decrease in water temperature). The technical
basis for Normalization is provided in the ASTM D5090 standard, however, membrane
manufacturers modify these formulas to allow better calibration and fit to the membrane
characteristics of their product as demonstrated in fiber construction and field operating
performance.

The basic idea of the Normalization practice is to eliminate the temperature effect from
the operational data, so that any deviation in membrane performance at same operating
conditions (e.g., same feed water quality, filtration cycle duration, same backwash and
chemical washes frequency, etc.) can be related to fouling phenomena. DOW™ UF uses
25°C as temperature of reference for data Normalization.

8.4.2. Normalization of DOW Ultrafiltration Performance Data

Dow uses a viscosity-temperature correction factor based on the latest expression for the
viscosity of liquid water from the International Association for the Properties of Water
and Steam (IAPWS, www.iapws.org/relguide/LiquidWater.htm).

The Temperature Correction Factor (TCF) follows Equation 2:

TCF 
890 (Eq. 2)
 1.9    7.7   19.6    40 
 280.68   TK     511.45   TK     61.131   TK     0.45903   TK  
  300     300     300     300  
      
Where:

TCF: Temperature Correction Factor, dimensionless.

TK : Temperature in Kelvin degrees (i.e., °C + 273.15).

The numerator is the dynamic viscosity of water at 25°C in Pa·s, the denominator is the
viscosity of water at the actual operating temperature. This expression results in a TCF of
1 at 25°C.

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