"Karaganda Pharmaceutical Complex" implemented a pilot project for water treatment based on the controller for reverse osmosis plants "KosMaster"

2023: Implementation of a pilot water treatment project based on the controller for KosMaster reverse osmosis units

In 2023, the Karaganda Pharmaceutical Complex enterprise in Kazakhstan implemented a pilot project to manage the reverse osmosis plant based on ARIES solutions. This was announced on November 21, 2023 by representatives of ARIES.

"Xmaster"

According to the company, according to the pharmacopoeia standards, premises in which samples of medicinal components and substances are taken under the laminar field are subject to increased requirements for sterility and purity. For cleaning "clean rooms" of class B with local area A, highly purified water corresponding to the quality of water for injections is used.

As part of the test tests, the Customer has integrated into the existing industrial reverse osmosis system, which is not equipped with an automation system, the KosMaster controller manufactured by ARIES. This is a unit with ready-made algorithms that controls high and low pressure pumps, systems that dose antiscalants. The functionality of the device meets the requirements of manufacturers of reverse osmosis membranes to maintain hydraulic modes during start-up, production and shutdown. The controller also provides protection against emergencies, for example, failures in the operation of various types of valves on clean water lines and in storage tanks and, depending on criticality, independently corrects deviations.

The device can be integrated into centralized enterprise dispatching systems without the presence of operators. It archives critical parameters such as electrical conductivity, pressure, temperature, frequency of flushing in continuous operation of the controller and the output of all emergency conditions. Monitoring the parameters of the "KosMaster" operation in real time is available when connecting to the OwenCloud remote dispatching service. For integration, the controller provides a RS-485 interface with the Modbus RTU exchange protocol.

The reverse osmosis unit together with the ARIES solution is used at the water demineralization stage according to the requirements of the pharmacopoeia "Highly-purified water" used for cleaning clean rooms. This task requires a small volume - about 100 liters per week, while the schedule of use is not balanced. With the help of the KosMaster 24.03 controller, the functionality of periodic drainage of water from the storage tank at night (at 2:00) is implemented with a long idle time. This makes it possible to exclude the formation of microflora, the accumulation of bacterial endotoxins from water treatment elements in the water distribution system.

The customer company also considers the use of the KosMaster controller in other reverse osmosis units used. This will reduce the risks of possible equipment failure, compensate for the lack of firmware for foreign-made controllers and ensure the ability to periodically start three-hour membrane washing during the repair period.

As of November 2023, we face certain difficulties in servicing reverse osmosis systems based on foreign controllers. More time is required to request and update the firmware, to start water treatment. As we tackle these problems, reverse osmosis membranes require constant maintenance or conservation and can be damaged. Therefore, an operational solution is important for us, which allows us to independently configure the equipment for our tasks. We have already started adapting the KosMaster device for existing projects, without waiting for a possible failure in the future. The main thing is that the algorithm for working with actuators (pumps, valves, behavior logic) corresponds to the European brands we operate, and the simple interface is easy for personnel training. emphasized Yuri Kurashevich, head of the metrology and instrumentation service of the Karaganda Pharmaceutical Complex

For industrial use in deep water treatment systems, Yuri Kurashevich recommended treated water treatment schemes based on two-stage reverse osmosis plants. Each stage is controlled by its own controller "KosMaster." In this case, it is possible to control the start-up of the second stage through the dosing pump control output. The second stage can also be an electrodeionization unit.

Unlike foreign solutions that offer a maximum of two conductometric inputs, KosMaster allows you to simultaneously connect four channels for monitoring the electrical conductivity of water at various stages of water treatment. The fourth conductometric inlet can also be used to monitor emergency flooding around the reverse osmosis system installation area. shared recommendations Yuri Kurashevich

The expert also shared the current problem facing industry experts.

Not all conductometers of industrial class make it possible to set the free value of the conductometric cell constant. Most foreign vendors offer fixed constants of 0.1 or 1.0. At the same time, for setting in practice, a larger range of values ​ ​ is needed. You can, of course, buy a "proprietary" cell, spending more than $400 on this, but it is much more convenient if the device already provides a large variability of values ​ ​ for calibration. added Yuri Kurashevich

When developing the reverse osmosis controller, ARIES relied on the versatility of the solution, taking into account the practice of use in water treatment systems. Device allows to monitor parameters of purified water, concentrated salt solutions, for example, effluents of reverse osmosis systems or pools with sea water.

We noted that when using the TDS (total dispersed solids) measurement function, the controller allows you to output the result in units of salt content with any user-acceptable conversion factor - 0.5-0.64-0.7 or others. We checked the specific conductivity readings with the conductometer at the permeate production site and during the control of the source water. KosMaster demonstrated accuracy in all measurement ranges with conductometric cells supplied with the instrument. Therefore, it can be used in addition to measuring means for analyzing the dynamics of seasonal variation in the quality of source water, desalination efficiency, monitoring of the permeate storage and distribution system. supplemented by expert