Leader Evaporator Springtech EXTREME 6 Manual de usuario

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Leader Evaporator Co., Inc.

49 Jonergin Drive

Swanton, VT 05488

Tel: 802-868-5444

www.leaderevaporator.com

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EXTREME 6

Reverse Osmosis System

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LeaderEvaporatorSpringtechEXTREME6ReverseOsmosisSystemManual Page:2

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TABLEOFCONTENTS

INTRODUCTION..........................................................................................................................................................................4

THEORYOFOPERATION..............................................................................................................................................................4

Terms..............................................................................................................................................................................................4

DescriptionofMembrane...............................................................................................................................................................5

EQUIPMENTDESCRIPTION..........................................................................................................................................................6

FRONTVIEW...........................................................................................................................................................................................6

REARVIEW.............................................................................................................................................................................................6

FEEDPUMP............................................................................................................................................................................................7

PRESSUREPUMP.....................................................................................................................................................................................7

RECIRCULATIONPUMPS............................................................................................................................................................................7

CONTROLPANEL.....................................................................................................................................................................................8

FLOWMETERS........................................................................................................................................................................................8

PRESSUREGAUGES..................................................................................................................................................................................8

SAMPLINGPORTS....................................................................................................................................................................................9

V1ANDV2VALVES.................................................................................................................................................................................9

FLOWCONTROLVALVES...........................................................................................................................................................................9

INCLUDEDEQUIPMENT...........................................................................................................................................................................10

OPTIONALSETUPEQUIPMENT,PARTSANDSUPPLIES....................................................................................................................................11

SETUP.......................................................................................................................................................................................12

AREAREQUIRED....................................................................................................................................................................................12

POWERREQUIREMENTS..........................................................................................................................................................................12

GENERALCONNECTIONLAYOUT...............................................................................................................................................................13

Simple3TankRODiagram...........................................................................................................................................................13

STRAINERTOVALVEV6CONNECTION.......................................................................................................................................................14

VESSEL,PUMP,PREFILTERCANISTERANDWASHTANKDRAINS....................................................................................................................14

V3,V4ANDV19CONNECTIONS..............................................................................................................................................................17

V19–ConnectionToDrain...........................................................................................................................................................17

V3–ConnectionToPermeateStorage.........................................................................................................................................17

V4–ConnectiontotheConcentrateStorage...............................................................................................................................18

OPERATION..............................................................................................................................................................................19

STARTUPOFSYSTEMWITHLITTLEORNOFLUID...........................................................................................................................................19

INITIALSYSTEMCLEANING.......................................................................................................................................................................20

DATALOGGING.....................................................................................................................................................................................20

CYCLESANDTIMING...............................................................................................................................................................................21

PERMEABILITYTEST................................................................................................................................................................................22

FLOWVALVEINFORMATION....................................................................................................................................................................25

ADJUSTINGV1ANDV2FOROPERATIONS..................................................................................................................................................26

SAMPLEPORTUSE.................................................................................................................................................................................26

CONCENTRATECYCLE.............................................................................................................................................................................26

DESUGARCYCLE....................................................................................................................................................................................29

RINSECYCLE.........................................................................................................................................................................................31

WASHCYCLE........................................................................................................................................................................................34

HotWaterWash...........................................................................................................................................................................34

AlkalineSoapWash......................................................................................................................................................................34

AcidSoak......................................................................................................................................................................................34

MAINTENANCE.........................................................................................................................................................................37

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LeaderEvaporatorSpringtechEXTREME6ReverseOsmosisSystemManual Page:3

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PREFILTERS...........................................................................................................................................................................................37

MEMBRANEREMOVALANDINSTALLATION.................................................................................................................................................39

Removal........................................................................................................................................................................................39

→CommonStepsforRemovalofMembranes.............................................................................................................................................39

→StepsforRemovalOfBrineSealClampedMembranes............................................................................................................................41

→StepsforRemovalOfThreadedRodClampedMembranes......................................................................................................................42

Installation...................................................................................................................................................................................43

→StepsforInstallaonofBrineSealClampedMembranes.........................................................................................................................43

→StepsForInstallaonofThreadedRodClampedMembranes..................................................................................................................45

CommonStepsforInstallation.....................................................................................................................................................................47

DAILY..................................................................................................................................................................................................48

PERIODIC.............................................................................................................................................................................................49

ENDOFSEASONSHUTDOWNANDSTORAGE...............................................................................................................................................49

BEGINNINGOFSEASONSTARTUP..............................................................................................................................................................51

TROUBLESHOOTINGCHART......................................................................................................................................................53

ATTACHMENT#1–ELECTRICALSCHEMATIC..............................................................................................................................54

ATTACHMENT#2–OPERATIONSDATALOGSHEET....................................................................................................................56

ATTACHMENT#3‐PERMEABILITYTESTSHEET..........................................................................................................................57

ATTACHMENT#4–WARRANTYINFORMATION.........................................................................................................................58

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LeaderEvaporatorSpringtechEXTREME6ReverseOsmosisSystemManual Page:4

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INTRODUCTION

ALeaderEvaporatorSpringtechEXTREMEReverseOsmosissystemisdesignedtosignificantlyimprovetheproducer’s

productivitybygeneratinghighsugarpercentagesap.Throughuseofhighpressure,thesystemremoveswaterfrom

thesapresultinginamoreconcentratedsugarsolutionenteringtheevaporator.Thisinturnshortenstheboiltime

requiredresultinginfuelandtimesavings.

SomeofthefeaturesoftheSpringtechEXTREME6are:

Easyaccessibilitytopumpsandmembranes

Stainlesssteelframe,membranehousings,pumpsandpumphousings

Fastwashcycle

Withreasonablesap–theabilitytogeneratehighbrixconcentratewithasinglepass

Flowmetersforthepermeateofeachvesselandoneforthesystemconcentrate

THEORYOFOPERATION

Inreverseosmosis,throughtheuseofspecialsemi‐permeablemembranesandhighpressure,waterisforced,ina

pureform,throughthemembranewhiletheconcentratedsolutionremainsoutsidethemembraneandis

concentrated.Forthesugarmakerthismeanswater(permeate)isremovedfromthesapandasapwithahigher

sugarlevel(concentrate)isproducedfortheevaporationprocess.

Terms

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Semi‐permeableMembrane–Unitconsistingofmultilayersofspacersandmembranes

Pre‐FilterUnit–Designedtoremovesuspendedsolidsfromthesapincomingtothereverseosmosissystem

FeedPump–Theinitialpumpdesignedtosupplythereverseosmosisunitwithsapandmaintainpressurein

thesystem

PressurePump–Thepumpdesignedtoprovidethepressureneededtoforcethesapthroughthereverse

osmosismembrane

PressureVessel–Thecontainmentunitforthesemi‐permeablemembrane

Permeate–Purifiedwaterremovedfromthemaplesapduringtheconcentratecycle

Concentrate–themaplesaphavingahigherpercentageofsugarbecausewater(permeate)hasbeen

removed

PermeateHoldingTank–Atankdesignedtoholdaminimumtwicethehourlyoutputofthesystem

ConcentrateCycle–ProcessduringwhichwaterisremovedfrommaplesapresultinginConcentrateand

Permeate

ReverseFlowConcentrateCycle–Concentratecycleinwhichtheflowthroughthesystemisreversed

allowingmoreevenuseofthemembranes

De‐SugaringCycle‐ProcesstoreclaimsugarsfromthemembraneduringwhichPermeateisrunthrough

thereverseosmosisunitusingConcentratecyclevalvesettings

RinseCycle–CleaningprocessofpassingstoredPermeatethroughtheReverseOsmosissystemandout

todrain

ChemicalWashCycle–Processofchemicalwashingthemembranesbyrecirculatingasolutionthrough

thereverseosmosissystem.Dependentonrequirement,chemicalmaybebealkalioracid.

PermeabilityTest–Testtodeterminetheperformanceofthemembranesagainstabenchmark

SapRecirculationLoop–Processofrecirculatingoutputfromtheconcentratecycletotherawsaptank,

increasingtheconcentrationofthesapinthetank

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LeaderEvaporatorSpringtechEXTREME6ReverseOsmosisSystemManual Page:5

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DescriptionofMembrane

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Thedrawingaboverepresentstheflowofliquidthroughamembraneinthesystem.Themembraneishoused

inapressurevessel(notshown).

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Thebasicunitsofthereverseosmosismembraneare

describedinthecrosssectiondrawing.

Attachedtothepermeatetubeisamembraneunit

consistingofapermeatecarrierbetweentwo

membranes.

Thereareanumberofthesemembraneunitsattached

aroundtheoutsideofthepermeatetube.

Betweeneachofthemembraneunitsisaspacer

throughwhichthesapandconcentratecanflow.

Thepermeatetubeisperforatedsothepermeatecan

becollectedfromthemembraneunit.

Ateachunitasthesapispressurized,thepermeate

canflowthroughthemembraneandbecarriedtothe

permeatetube.Theconcentratecannotpenetratethe

membraneandispushedoutthemembraneassembly.

Themembraneunitsarewoundaroundthepermeate

tubeandanoutsidesupportstructureisplacedaround

thewoundassembly.

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LeaderEvaporatorSpringtechEXTREME6ReverseOsmosisSystemManual Page:6

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EQUIPMENTDESCRIPTION

TheLEADEREVAPORATORSpringtechEXTREMEReverseOsmosisSystemisdesignedtooffermaximumconcentration

tocostperformance.Throughoptimizingofpumpsandmembranesthereverseosmosissystemsdelivergreaterflow

potentialtotheuser.TheLEADEREVAPORATORSpringtechEXTREMEReverseOsmosissystemisdesignedandbuilt

usingthesameprinciplesofsuperiorqualityappliedtoourevaporators.

TheLEADEREVAPORATORSpringtechEXTREMEReverseOsmosisSystemiscoveredbyamanufacturer’swarranty–

SeeATTACHMENT#4.

NOTES:

1. Pictures,sketchesanddrawingspresentedinthisdocumentarenottoscale.

2. Directions(rightandleft)willbeasfacingthefrontofthesystem.

3. Thefeedpump,prefiltersandwashtankaremountedasaseparateunittobeattachedtothemainsystem.

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FrontView

Prefilterhousingrequires

five(5)–20”cartridge

filters.

RearView

Washtankisusedtomix

thechemicalsolutionfor

cleaningthesystem

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LeaderEvaporatorSpringtechEXTREME6ReverseOsmosisSystemManual Page:7

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PressurePump

Secondstageofpressurizingthe

systemrequiredtoprocessthe

sapthroughthemembranes

RecirculationPumps

Recirculatesliquidwithinthe

vesseltowhichtheyareattached.

FeedPump

FeedPumpprovidesliquidtothe

systemandisthefirststageof

pressurizingthesystem



LeaderEvaporatorSpringtechEXTREME6ReverseOsmosisSystemManual Page:8

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ControlPanel

Startbuttonwhenpressedstartsthesystempumpsin

sequence.

TheSTOPorSTOP/ALARMRESETbuttonisamaster

resetforallthealarmsandwillstopthemachine

whenpressed.

TheTemperatureMeterindicatesthetemperatureof

theliquidflowingthroughthesystem.

PressureAlarmindicatesapressureconditioninthe

systemrelatedtothepressurepumprequirements.

Thealarmlightmaybesolid(lowpressure)orblinking

(prefilter).Thisalarmcanbepartofnormal

operations.Themachinewillshutdownwhenthe

indicatorlightisactivated.

HighTemperatureAlarmindicatestheWashcyclehas

completed.Thisalarmispartofnormaloperations.

Themachinewillshutdownwhenthealarmlightis

on.

MotorFailureAlarmisdueamotorcontactor

tripping.ContactLeaderEvaporator.

FlowMeters

TheConcentrateMeterindicatestheliquidflowfrom

theconcentratesideofthepressurevesselsingallons

perminute.

ThePermeateMetersindicatethepermeateflow

fromeachvesselingallonsperminute.

PressureGauges

Feedpumppressureisreadaftertheprefilters.

Membranepressureisreadafterthelast

membrane.

WARNING:DONOTALLOWTHEOPERATING

PRESSURETOEXCEED550psi.

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LeaderEvaporatorSpringtechEXTREME6ReverseOsmosisSystemManual Page:9

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SamplingPorts

Concentrateportisusedtosampletheliquid

concentratetodeterminethesugarpercentage.

ThePermeateportsareusedtosamplethepermeate

fromthevesselstodetermineifthemembranesare

allowingsugartopassthrough.

V1andV2Valves

V1controlsthepressuretothemembranes.It

isopened½waywhenstartingthenadjustedto

reachthepressurewanted.CloseV1toraise

thepressureinthesystem.

V2controlstheflowfromtheconcentrateside

ofthemembranes.Itisopened½waywhen

startingthenadjustedtothedesired

concentrationlevel.

FlowControlValves

Thesevalvescontroltheflowofliquid

throughthesystem

V3–Permeateflow

V4–Concentrateflow

V6–Feedflow

V18–CleaningorConcentrateflow

V19–DrainorWashTank



LeaderEvaporatorSpringtechEXTREME6ReverseOsmosisSystemManual Page:10



VALVETYPE

HANDLE

POSITIONLIQUIDFROM‐TO

HANDLE

POSITIONLIQUIDFROM‐TO

V33‐Way

HANDLE

POINTED

HORIZONTAL

MembranestoPermeate

out

HANDLE

POINTED

VERTICAL

MembranestoValve

V19

V43‐Way

HANDLE

POINTED

VERTICAL

MembranestoConcentrate

out

HANDLE

POINTED

HORIZONTAL

MembranestoValve

V19

V63‐WayHANDLE

VERTICALExternaltoFeedPump

HANDLE

HORIZONTAL

WashTanktoFeed

Pump

V182‐Way

HANDLE

POINTED

HORIZONTAL

NoFlow

HANDLE

POINTED

DOWN

MembranestoValve

V19

V193‐Way

HANDLE

POINTED

HORIZONTAL

MembranestoWashTank

HANDLE

POINTING

VERTICAL

MembranestoDrain



TheLeaderSpringtechEXTREMEReverseOsmosissystemconsistsofthefollowingparts:

IncludedEquipment

ITEMLEADER

ORDER#DESCRIPTION/PHOTOITEMLEADER

ORDER#DESCRIPTION/PHOTO

Springtech

EXTREME6

700068



Springtech

EXTREME6User

Manual



Springtech

EXTREME6

QuickStart

Guide



1–1/2”Quick

CouplerC

Qty:2

47160

1”Quick

CouplerC

Qty:1

47148

2”Threadedto

3”Slip

Connector

195



StrainerY

3”modified

withbleeder

valve

70141







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