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Number : LS-WI-FM-01-09
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WORK INSTRUCTION

REVERSE OSMOSIS PLANT

APPROVAL SHEET

Name Title Signature Date

FM Assistant
Approved by
Muhammad Husaini Manager

ISO / OHSAS
Reviewed by Wiwit Cahyono Management
Representative

Prepared by Rusjito RO Supervisor

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 Doc. Number : LS-WI-FM-01-09
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Document Custodian : Facility Maintenance Department

REVISION HISTORY SHEET

REVISION # PAGE # DESCRIPTION OF CHANGE ISSUED DATE

0 All New Work Instruction 01-02-2018

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 Doc. Number : LS-WI-FM-01-09
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1.0 Precondition
1.1 Reverse Osmosis Plant is normal condition
1.2 Any Feed water (Sea Water)
1.3 Operator must use PPE to operate the engine

2.0 Description
2.1 General
All mechanical/electrical equipments, including all instrumentation shall be checked and
prepared before start-up op the Plant. The following shall be executed in the preparation;
2.1.1 Execute a careful visual inspection for loose, broken or damage components, control,
gauges, and so on. Defective parts should be repaired and calibrated correctly.
2.1.2 Confirm that all laboratory equipment is available since water analysis must be conducted
on starting the RO units
2.1.3 Check that first Aid supplies are available
The below instructions are intended to guide qualified operating personal in the operation
Reves Osmosis units. This manual may not cover all possible contingencies. Careful
attention to the valves of temperature, pressure, flows and alarm system should be paid
attention.
Control Mode
All motor driven equipment shall be started and stopped from control panel
Raw Water Quality
The raw water quality shall be analysed at regular intervals (every month)
Utilities
Check that the following utilities are available with their design Values, Power, Chemical
and Plan service water.
2.1.4 Flushing
In order to prevent the equipment from damage by foreign matters, the following flushing
procedure should be conduct.
2.1.5 Piping
Before flushing the pipe line, all block valves and control valves shall be fully opened and
insulation valves for instrument are closed. Nozzle of equipment will be blinded to prevent
equipment from ingress of foreign matter. Insert temporary strainers to suction line of all
pumps. Flushing have to be done with clear water and continue until foreign matter is no
longer present. Flush water will be drained through the piping drain valve or gap of

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flanges.
2.1.6 Media Filter
Filter Media should be backwashed until low turbidity water is obtained. Before operation
of RO unit, SDI of filtered water should be less than approximately 3.0
2.1.7 Cartridge Filter
Before flushing cartridge filter elements shall be removed. And after flushing cartridge filter
vessel and should be properly bolted. During replacement of filter elements and take care
to avoid damaging the elements.
2.1.8 Revers Osmosis Membranes
Before putting the system into the operation, the membranes should be flushed with water
low pressure (by transfer pump).

2.2 Reverse Osmosis Plant Operation

2.2.1 General
The RO system has been design to run with a minimum amount of attention, no
adjustments are therefore required under normal circumstances
Exactly how the system is operated depends on the water demand cycle. It’s
recommended that the auto-mode be used as soon as the system is started up. Initially,
the operation of the plant should be monitored rather closely with the operator checking
the system every hour depending on plant running condition, parameter to check.
All new machinery needs a “Shakedown” period, and a RO Plant is no exception. After
the initial start up, the system needs to be checked out at least every second hour. If
water demand or supply is extremely variable, close supervision may be necessary.
Each time the system is checked and entry should be made in the operation log.

2.2.2 Daily Routine Checks

Fill in the data various operation log. The daily check should consist of the following:
2.2.2.1 Carry out daily routine jobs and checklist
2.2.2.2 Check and record all R.O instrumentation including meter. Be aware of
any drastic changes from previous reading.
2.2.2.3 Record filter in let and out let pressure. Oversee that the filter is
backwash if pressure drop is more than what set for (Typically 1 bar).
Record the Cartridge Filter pressure read from the pressure gauge on

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filter. Change of cartridge if pressure changes by so much as 100Kpa

(14.5 psi) by opening the housing and replacing the cartridge.
2.2.2.4 Check and record raw water and filtered water test
2.2.2.5 Check and record the product quality. Be aware of any significant
changes from previous reading.
Note:
A change in product quality accompanied by change in quantity could indicate problem
developing – rever to the trouble shooting guide.
After the above log entries are made and check following:
Level chemical Dosing Tanks:
- Natrium Hidroksida (NaOH) Dosing Tank
- Ferric chloride (FeCl) Dosing Tank
- Anti Scalene ( Envira E-610) Dosing Tank
- Acid (H2SO4) Dosing Tank
- Sodium Hypoclorite (NaOCl) Dosing Tank
2.2.3 RO Plant Shutdown
If there a need for stopping RO units this can be done manually by switching the selector
on the Electric Panel
2.2.4 Duties Operator
In general terms, the duties of a Plant Operator my be described as list below:
2.2.4.1 To ensure that the plant consistently produce a water
No lower quality than it was designed to produce
2.2.4.2 To see that all operating details are performed promptly and efficiently.
2.2.4.3 To systematically monitor and record different process parameters
including chemical consumption
2.2.4.4 To carry out or arrange for all required laboratory analysis and test of the
water passing through the plant as to maintenance proper efficiency in
operation
2.2.4.5 To maintain all equipment and structures of the plant in good order and
condition
2.2.4.6 To keep proper records of Operation & Maintenance
2.2.4.7 To ensure all precautions necessary for the safety of personnel and
property are observed
2.2.4.8 To bring the notice of the Supervisor any alteration work or facilities which
may be necessary to place or maintenance the plant in efficient operation

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2.2.5 General Operation requirement

2.2.5.1 Feed water temperature must be in the range 17°C and 35°C
2.2.5.2 Feed water pressure at inlet to High Pressure Pump should be at least
200 Kpa (2 bar) when the High Pressure Pump operating. This low limit is
required in order to overcome the pressure drop of the filters and to
prevent activation of the Low Feed Pressure Switch and still not start the
High Pressure pump.
2.2.5.3 Pre-filtration equipment is included with system. The cartridge filters will
retain particles down to 5 microns in the feed water and protect the High
Pressure Pump
2.2.5.4 The Silt Density Index (SDI) at the membranes must be held to less than
3.0
2.2.5.5 The pH level is governed the incoming water flow quality
2.2.5.6 Anti Scalene is automatically injected when the high Pressure Pump
running. Ensure that there is an adequate quantity of scale-inhibitor in the
storage tank.
2.2.5.7 Product back pressure must be held below 7 kPa (0.7 Bar) otherwise
performance is impeded.
2.2.5.8 The concentrate line (brine) must be free-following (vented to
atmosphere) this to prevent backpressure. An external shut-off valve may
be installed in the feed line. Under no circumstances should valve or
other isolating devices be installed in the permeate (product) line without
consulting. The discharge into the drinking storage tank must be open
ended (vented to atmosphere).

2.3 Equipment Operating Procedure

2.3.1 Sea Water Intake Pumps
The source of raw water is from open sea intake and received into the filter water tank after
pre-chlorination and filtration
2.3.2 After loading the filter media for Dual Media Filter,
Select DMF in manual mode from the control panel and skip the backwash step to rinse
mode.
Select one of sea Water Intake Pump in manual mode and discharge valve, service inlet
and outlet valve of DMF. Start the pump for 15 to 20 minutes to backwash the DMF.

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Note: Normally backwash will use filtered water using back wash pump after DMF produce
the filter water
2.3.3 Select the DMF for rinse step.
Start the sea Water Intake Pump and feed water pump, manually for one hour. During
rinsing check SDI from the DMF. The SDI should be less than 3 after rinsing keep the filter
in standby mode
If a filter is full of water and already un operated more than two days should be backwash
first before production.
2.3.4 Dual Media Filter Shutdown
To take filter completely off-line, select the filter in standby mode from the control panel and
close the filter Service inlet and outlet valves
Maintenance the Filter, open the drain valve at bottom of the filter and open the backwash
outlet vales. This will depressurize the filter and after empty close the drain valve.
2.3.5 Dual Media Filter Normal Operation
Check the inlet and outlet pressure gauges, the pressure should differential read
approximately 5-6 PSI (not more than 15 PSI with design flow 65 M3/h). SDI should be
tested once a day
2.3.6 Dual Media Filter Backwash
Filter shall be backwash if meets any of the following:
2.3.6.1 If the High pressure drop (differential 15 Psi)
2.3.6.2 After run for 24hours
2.3.6.3 After out of service more 24 hours

2.4 Cartridge Filter

2.4.1 Operation of the Cartridge
2.4.1.1 Before operate the Cartridge filter RO feed water must meet specification of feeding to
the RO membranes
2.4.1.2 Select DMF in service mode and start one of the filtered feed pumps manually.
2.4.1.3 Slightly open the inlet valve of cartridge filter allows RO feed water to pressurize the
filter. Once the filter is pressurized slowly open the outlet valve. Repeat the procedure
until all operational cartridge filters are pressurized.
2.4.1.4 Fully open the cartridge filter outlet valve when the RO units are ready to start.
2.4.2 Cartridge Filter Shutdown
Coordinate the shutdown of cartridge filter to the RO units. Take the cartridge filters off
line by first closing the out let valve then close the inlet valve.

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2.4.3 Normal Operation

Cartridge filter operated manually, Operator’s attention is required to coordinate with the
operation of the RO units.
The operator shall monitor system differential pressure to determine when cartridges should
be replaced.
When cartridges are new the differential pressure will be less than 35kpa (5Psi). And when
all cartridge dirty and should be replaced or will different 15psi. Record the inlet and outlet
pressure one per shift
2.4.4 Cartridge Element Changing
2.4.4.1 Shut the cartridge filter valve inlet and outlet
2.4.4.2 Open the drain valve and release pressure from the vessel and unscrew the end plate of
cartridge filter housing.
2.4.4.3 Remove all the old filter cartridges
2.4.4.4 Fit the new filter cartridges
2.4.4.5 Fit the end plate back to original position
2.4.4.6 Open the filter inlet and outlet valves to it back to service.
2.5 Reverse Osmosis System
2.5.1 RO initial Star-Up
 Before feeding the water to the RO membranes the feed water must meet the
specification
 Put the RO units into operation only if the pressure storage tank is ready to receive the
water
 Lead the RO membranes as per the membranes loading procedures.
2.5.2 Before starting the high pressure pump, start the low pressure flushing with filtered water
pump as per the following procedure:
 Open valve service inlet and outlet of cartridge filter manually
 Turn “ON” filter pump A/B/C from the control panel
 Feed water will pass through the membranes at low pressure
 Duration of low pressure flushing is ± 15 minutes
2.5.3 After low pressure flushing prepare to RO for start-up
 Select filter water pump and Turn “ON” and oven the valve by manually and turn “ON”
the RO system.
2.5.4 The system will start by following steps:
 One of filtered water pumps A/B/C will start with one Antiscalant Dosing and at the same
time feed valve and reject by pass valve will open automatically

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 30 seconds timer will start from this point. After 20 seconds check was carried out for
flow low-pressure reading (PSL), if it is within the range then the high pressure pump will
start and reject bypass valve will close. If the end of 30 seconds still there is low
pressure then the system will stop with alarm.
 High pressure pump discharge line is equipped with high pressure switch interlocked
with pump to shutdown in case of high pressure to RO
 Adjust the permeate flow and reject flow by controlling the reject valve. (permeate flow
4.5 m3/hr and reject flow 8.5m3/hr)
 Conductivity meter is provide in RO permeate line and flow meters are provided in RO
permeate and line flow meters are provided in RO permeate and feed line.
 RO permeate is collecting into the drinking storage tank
2.5.5 RO Normal Operation
Normal operation of the RO unit involves pre-treatment units. Operator’s attention is
required to monitor system operation and changing feed water condition.
The membranes must be protected against high pressure switch and low pressure switch.
The manufacture’s guidelines for operating temperature and pressure are follows.
The membranes must never be exposed to feed water-containing chlorine to a void rapid
deterioration.
The Operator shall regularly check all of above parameters
2.5.6 RO Shutdown
a. To accomplish a normal shutdown, stop the high pressure Pump by pressing stop push
button on the control panel
b. High pressure pump is electrically interlocked to shutdown if one or more of the following
occurs:
c. The low pressure switch PSL detects low suction pressure. In addition to shutting down the
pump, this will also sound an alarm on the panel.
d. A high pressure switch PSH detects the High Discharges Pressure. In addition to shutting
down the pump, this also sound an alarm on the panel
High conductivity on the permeate side will give sound an alarm and shutting down the
pump.

3.0 Record
3.1 Maintenance Check List – FR-19-LS-SOP-FM-01

4.0 References document

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4.1 Preventive Maintenance Procedure LS-SOP-FM-01

4.2 Preventive Maintenance Plan schedule FR-32-LS-SOP-FM-01
4.3 Work Instruction Corrective Action LS-WI-FM-018

5.0 Retention Period

This document will be available in FM Office for two years in reference from the date of review
6.0 Appendices
REVERSE OSMOSIS PLANT FLOW
DIAGRAM

SEA WATER

H2SO4

FeCl

DUAL
MEDIA
FILTER

FEED
WATER
TANK

E610

CARTRIDGE
FILTER
NaOCl

NaOH

CARTRIDGE
FILTER

MEMBRANE
TANK WATER
PRODUCTION
FLUSHING

STORAGE

WATER
TANK

REJECTED DISTRIBUTION

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