The device described in this manual is the NEW12 ES60 Reverse Osmosis Watermaker, manufactured by OSMOSEA SRL. It is a water treatment plant designed to produce freshwater from seawater through the process of reverse osmosis.
Function Description
The NEW12 ES60 operates on the principle of reverse osmosis, a water filtration technique that forces solvent molecules from a more concentrated solution to a less concentrated one by applying pressure greater than the osmotic pressure. This process utilizes a membrane that retains solutes on one side while allowing pure solvent (freshwater) to pass through. The system is designed for desalination and removal of various pollutants, including phosphates, calcium, heavy metals, pesticides, and radioactive materials.
The plant includes several key components:
- Feed Pump: Draws seawater into the system.
- Prefilter (5 micron): Removes suspended solids from the incoming water, acting as a security feature for the plant's operation.
- Flushing Carbon Filter: Used for flushing the system with clean water.
- Pressure Intensifier: Increases the pressure of the water to facilitate the reverse osmosis process.
- Osmosis Membrane Vessel: Contains the reverse osmosis membrane, where the actual desalination occurs.
- Post Carbon Filter: Further filters the produced freshwater.
- Solenoid Valve: Controls water flow within the system.
- High Pressure Switch and Low Pressure Switch: Safety devices that monitor and control system pressure.
- Inlet Pressure Manometer: Displays the inlet pressure.
- Remote Control and Comand Unit: Provide user interface and control for the system, including START, STOP/RESET, FLUSHING, and PRIMING functions.
- Brushless Motor Driver: Powers the system's motor.
The system's flow pattern involves seawater entering through a thru-hull, passing through the seaweed filter, non-return valve, and feed pump, then through the prefilter, pressure intensifier, and membrane vessel. Freshwater exits through the post carbon filter, while brine is discharged. A flushing circuit is also integrated, using a flushing solenoid valve and carbon filter.
Important Technical Specifications
Operational Parameters:
- Type of operation: Single passage
- Pressure: 55/60 bar
- Working Temperature: 15°C / 25°C
- Minimum temperature allowed: 3°C
- Maximum temperature allowed: 40°C
Membrane Features:
- Configuration: Wrapped spiral
- Materials: Film Composit
- Dimensions: 2.5" x 40"
- Maximum temperature allowed: 40°C
- Quantity: 1
Electrical Features:
- Voltage: 24 V dc
- Maximum power installed: 300 W
- Electrical panel class: IP 65
Wiring Connections:
- The manual provides a wire size guide based on length to ensure proper performance and prevent voltage drop. For example, 6 mm wire for up to 15 feet (4.5 mt), 10 mm for up to 25 feet (7.5 mt), and 16 mm for up to 35 feet (10.6 mt).
- The system should be protected with a 16 Amp Fuse or Circuit Breaker.
Plumbing Connections Sizes:
- Sea water inlet: Armovin hose (16 mm)
- Freshwater exit: PVC hose (8 mm)
- Drain exit: Armovin hose (16 mm)
- Flushing inlet: Armovin hose (16 mm)
Usage Features
Installation:
- The plant should be installed in a well-illuminated area, on a solid, level foundation, away from vibrations.
- The seawater pump should be positioned as low as possible, ideally below the waterline.
- A dedicated 3/4” forward-facing scoop-type intake thru-hull and seacock are required. The thru-hull should be installed as far below the waterline and as close to the center line as possible to avoid contamination and air intake.
- The brine discharge thru-hull should be mounted above the waterline.
- Piping connections are push-fit. All hose connections below the waterline must be double clamped.
New System Start-Up:
- Before starting, ensure thru-hull inlet and brine discharge valves are open, hose connections are tight, and the pressure relief valve is open.
- The PRIMING selector is used to activate the feed pump and ensure water flow in the inlet hose, with pressure sensors temporarily switched off.
- After priming, the RELIEF VALVE PRESSURE is closed, and the system is started by pressing START on the control panel.
- The inlet pressure should be maintained between min. 10 bar and max 15 bar.
- Operation in waters below 10°C (50°F) may cause high operating pressures and increased wear on the feed pump.
Watermaker's Shutdown:
- Press the STOP key and close the Seawater inlet.
Flushing:
- A flushing cycle is necessary if the plant is stopped for longer than 3 days. This is initiated by pressing the FLUSHING key.
- For stops longer than 10 days, a membrane preservation procedure is required to prevent microorganism proliferation.
Maintenance Features
Daily Maintenance:
- Membranes: The most delicate part of the plant. They must always be kept wet and not exposed to temperatures outside 3°C to 40°C. If outside temperature falls below 3°C, 20% glycerin should be added to washing water to prevent ice formation. All membrane inspection or replacement operations should be carried out by OSMOSEA SRL staff.
- Feed pump and Osmosea pressure intensifier: Require routine inspection for leaks. Hose clamps and fittings should be tightened if leakage is observed. High-pressure fittings should not be over-tightened.
- Pipes and high pressure circuits: Periodically check for deterioration and water losses.
- Pre-Filter: The pre-filter cartridges need maintenance if the inlet pressure drops more than 30% or if the exercising pressure is not steady. This indicates clogging or deterioration of the cartridges, which must then be replaced.
Extra Maintenance (Membrane Preservation):
- This procedure is performed for stops longer than 10 days (or 3 days if outside temperature exceeds 30°C).
- It involves opening the pressure relief valve, unscrewing and washing the 5-micron pre-filter housing, and then performing a closed-cycle flushing with a CLEANER B solution.
- The process includes filling a bucket with clean, non-chlorinated water, connecting it to the feed pump, sucking the water, then repeating with a CLEANER B solution, and finally leaving the plant full of this solution. Filter cartridges must be replaced before the next use.
Membrane Replacement:
- This procedure should be performed before long winter breaks and repeated every 6 months.
- It involves removing power, unscrewing and removing high and low-pressure pipes, removing vessel caps and half-moons, extracting old membranes, lubricating O-rings with silicone grease, inserting new membranes, and reassembling the system.
- All disassembly and reassembly procedures must be done with the plant shut down, in a safe and adequately equipped environment, and all parts thoroughly cleaned, scoured, or lubricated as needed.
Demolition and Disposal:
- At the end of its operational life, the plant must be disposed of in compliance with legal regulations. This involves general cleaning, separation of individual components (electrical equipment, ferrous/non-ferrous metals), and then proceeding with the disposal of different materials. No components require disposal through special government departments.
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