Successfully Installed 2000 LPH Commercial RO Plant at Boutique International, Gurgaon
Consistently treated water is important for commercial and industrial operations that rely on water consistently and continuously. The composition of raw water, including dissolved salts, hardness, suspended matter and other water properties, can vary and impact the usefulness of the raw water for drinking, utilities, processes. The combination of appropriate pretreatment with membrane purification would present an effective solution provided by a suitably designed commercial RO plant. The RO plant of 2000 LPH Commercial RO Plant was successfully installed and commissioned at Boutique International, Gurgaon and they were provided with a reliable source of treated water of about 2000 litres per hour based on the operating conditions provided.
Boutique International is a vertically integrated garment Export Company based in Gurgaon. It has knitting, embroidery, printing and other apparel manufacturing activities and is manufactured in its facility in Gurgaon.
The project reflects our expertise as a Commercial RO Plant Manufacturer in Gurgaon and most importantly, designing treatment systems as per the plant requirements, feed water quality available at the site, output capacity required and operational needs of the client.
Project Overview
The aim of the project was to supply a viable commercial scale water treatment plant for Boutique International that will produce 2,000 litres per hour of treated water.
The quantity of water required is not the only factor to consider before installing a commercial RO plant, the characteristics of the feed water must also be taken into account. RO membranes are primarily meant to separate the dissolved contaminants from water, and pretreatment is used to abate suspended particles, scaling, etc., that can impact the membrane.
Thus, it was decided that the solution will be an integrated treatment system instead of a standalone RO membrane unit. The removal of material from the raw water, generating the pressure, separation in a membrane, monitoring and treating the water out of the membrane were all taken into account, in order to ensure the plant’s operation under commercial conditions.
The project involved site assessment, capacity planning, equipment selection, system fabrication, transportation to the facility, installation, electrical and plumbing connections, flushing, trial operation, parameter adjustment and final commissioning.
The system once installed, gives Boutique International a separate RO water-treatment system of 2000 LPH for assured everyday operation.
Client Details
Boutique International is a garment manufacturing and export company from Gurgaon, Haryana, which was the client for this project.
Boutique International calls itself the star export house for apparel brands in the United States and Europe recognised by the government. The company claims its manufacturing process is vertically integrated, that is all the process from yarn to finished goods are done at the company’s facility. It has the facilities of circular knitting, flat knitting, embroidery and printing.
Infrastructure reliability is crucial in an organisation that operates at this level. All water-treatment facilities need to be able to deliver the treated water needed in the required quantity, and not make routine operation and maintenance unnecessarily complex.
The need was thus for a commercial system, not a small domestic purification system. The chosen capacity of 2000 LPH was deemed to be an appropriate balance of the water demand, operational capability and future utility.
Project Location
The commercial RO plant was installed in Boutique International, Plot No. 553, Pace City 2, Gurgaon, Haryana – 122016.
The town Gurgaon or Gurugram has emerged as a very important business and industrial hub in Delhi NCR region. The nature of water may vary greatly depending on whether it comes from a municipal water supply, a ground water well or a tanker.
So, it is not right to choose commercial RO plants only on the basis of the rated production capacity. The characteristics of the feed-water, treatment time, and pretreatment time, storage facilities, and the water quality to be expected after treatment, must also be taken into account.
As a Commercial RO Plant Manufacturer in Gurgaon, we therefore do not follow a one design fits all principle instead we ensure that the treatment configuration is personalized to fit the actual site needs.
Plant Capacity
The rated treated water production of the installed plant is: 2000L/h (Litres per Hour)
| Parameter | Value |
| Rated Treated Water Production | 2000 L/h (Litres per Hour) |
The system can generate around 2000 litres of RO treated water in an hour when operated at its full capacity. The actual daily production will vary depending on the operating time, feed-water condition, membrane performance, maintenance condition, and water need of the facility.
The theoretical production capacity of a 2000 LPH plant is, for example, about 16 000 litres during a period of 8 effective production hours. But the plant does not have to run around the clock—operation can be synchronized with treated-water storage and actual consumption.
The capacity selected is enough for commercial scale output, while treated water production and storage will follow the facility’s production schedule.
Treatment Technology
The RO process with the proper pre-treatment technology represents the main treatment process adopted in the plant.
Reverse osmosis is a method that uses pressure to push feed water through a special membrane to extract some of the water. This results in two streams of water, the purified water or permeate, and a more concentrated stream of water called the concentrate or reject water, which contains the dissolved substances that were not purified. RO is a membrane-separation technology capable of separating a wide spectrum of dissolved contaminants and salts.
But RO membranes should not be fed inadequately treated feed water. Scaling compounds, suspended matter, and chlorine and organics may have an impact on membrane life and performance.
Influent Characteristics
Incoming water quality is one of the most crucial factors to consider while designing any commercial RO plant.
Dissolved salt, minerals which form hardness, suspended solids, turbidity, chlorine and organic matter can be found in varying amounts in commercial feed water.
The treatment system was designed to address the key parameters, which typically affect commercial RO operation, such as:
Total dissolved solids, hardness, suspended particles, turbidity, scaling potential and contaminants that could impact the performance of the membrane.
Pretreatment is particularly important because it is not only to enhance the quality of the feed water, but to avoid fouling or scaling of RO membranes before they are used. DuPont says proper pretreatment ensures good RO performance and that the pretreatment required is a function of the chemistry of the raw water and the purpose of the treated water.
If the water is to be used for drinking, it is prudent to test its final quality with the right tests. The drinking-water specification of Bureau of Indian Standards (BIS) IS 10500:2012 suggests that the acceptable range for TDS is 500 mg/L and permissible range is 2,000 mg/L without any source. This same standard establishes acceptable hardness levels between 6.5 and 8.5, as well as limits for chloride, fluoride, nitrate and many other parameters.
| BIS IS 10500:2012 Parameter | Value |
| TDS – Acceptable Range | 500 mg/L |
| TDS – Permissible Range (No source) | 2,000 mg/L |
| Acceptable Level | 6.5 to 8.5 |
Treatment Process
The 2000 LPH Commercial RO Plant is designed to pass through a series of treatment stages that help prevent damage to the membranes and assure a consistent product-water quality.
The raw water is pumped into pretreatment section first. The suspended matter is filtered out initially and the load is reduced to the later filter elements.
The water is then filtered through media filters. This stage is useful in controlling turbidity, suspended impurities, colour, odour and substances which may affect the operation of the RO membrane depending on the nature of the raw water.
When incorporated, activated carbon treatment acts as an important barrier to protect the membranes from the presence of chlorine and some of the organic compounds before they reach the membranes. This is especially important since improper feed-water conditions can adversely affect the performance of the membrane.
Fine cartridge filtration is another physical barrier to small suspended particles that is offered before membrane treatment.
A high-pressure pump is used to pump the pretreated water to the RO section. Reverse osmosis requires pressure due to the natural tendency of dissolved salts to move across a semi-permeable membrane.
The feed flows inside the RO membrane housing, splitting into a product water and a concentrate stream. Water passing through the membrane becomes the product water and continues to treated water storage, while a higher concentration reject water stream removes a significant amount of the dissolved substances separated.
During operation, flow and pressure parameters are monitored along with water quality parameters to detect any abnormal conditions and correct them.
Major Equipment
The main components needed for the pretreatment, membrane purification, monitoring and controlled operation were set up in the commercial RO system.
The major functional equipment consisted of:
| Equipment |
| Arrangements for feeding raw water and water feeding pump. |
| Pressure/media filtration system |
| Activated Carbon Treatment, when needed based on feed-water conditions |
| Antiscalant dosing arrangement |
| Micron/cartridge filtration |
| High-pressure RO pump |
| Monitoring of product-water and reject-water flow. |
| Temperature and operating controls |
| Electrical control panel |
| Interconnection of piping, fittings and valves. |
| RO-treated-water outlet/storage connection |
The equipment size was scaled to the product water requirement of 2000 LPH and operating condition.
The design also took ease of operation and maintenance into account since the installation of successful commercial water treatment relies not only on a good installation, but also regular monitoring, changing filters, maintaining membranes and timely servicing.
Installation Process
Installation started by surveying the plant space and existing utility services.
RO skid and pretreatment equipment were located for good accessibility for future maintenance and filter change out. The positioning of equipment is especially critical in commercial installations as the layout could become unnecessarily complicated to service the equipment routinely.
The inlet plumbing for raw water was connected to the pretreatment system, and connections between the treatment stages were made. Careful checks were made on the high pressure line, membrane housings, product-water outlet and reject water discharge line.
Pumping and dosing equipment and the control panel were electrically connected. The system was then checked for correct positioning of the valves, piping alignment and leaks.
With mechanical and electrical connections checked, individual system sections were ready for flushing and start-up.
Installation method – The approach was designed to reduce disruption to the client’s existing operations and provide easy access to the water-treatment equipment for future maintenance.
Plant Commissioning
Commissioning is one of the most important phases of a commercial RO project as good installation does not guarantee good operation.
The system was initially flushed to clear any loose material that may have been encountered during installation, and to ready the filters and membrane system for use.
The pumps were then gradually started and increased pressure applied in a controlled manner. The feed-water flow, product-water flow and reject-water flow were monitored as the system approached normal operating conditions.
The team inspected the system for leaks, abnormal pump performance, pressure and flow blockages during the commissioning. RO operating parameters were optimized for stable operation, while avoiding undue stress to the membranes.
The product-water output has been validated with the desired capacity of the plant, namely 2000 LPH subject to the condition of operating conditions and the quality of feed-water.
Routine startup and shut down, pressure monitoring, cartridge-filter replacement, chemical dosing, membrane cleaning indicators and preventive maintenance were also discussed with the operators.
Treated Water Reuse
The water that is treated through RO system can be stored in a separate tank, and can be pumped to specific locations where the facility needs low TDS water.
RO treated water can be used to prepare drinking water, to meet pantry needs, for utility uses and for appropriate process water needs based on the client’s internal water-management plan, where controlled dissolved-solids levels are desired.
For any end use, the distribution should be the same as the required water quality specification. If the water is used for drinking, the proper post-treatment, hygienic storage and regular microbiological and chemical testing are essential.
Concentrate management is also responsible for RO concentrate. Facilities may consider whether they can make a suitable non-potable use of the reject-water stream depending on its quality and the local needs. Testing and the needs of the intended use should be considered when making a reuse decision.
Results and Performance
The installation and commissioning of 2000LPH Commercial RO Plant at Boutique International, Gurgaon was a great success, it gave the facility its own high capacity treatment system to produce purified water there.
The main aim of the project, which was to set up a reliable RO water production system with a rated capacity of around 2000 litres per hour was achieved.
After commissioning, the stable operation of the system with controlled feed pressure, product-water generation, and reject flow were identified. The RO membrane stage achieved high removal of dissolved mineral matter from the feed water, and pretreatment prevented particulate and scaling loading of the membrane system.
The primary operational advantages of the installation are the assured commercial scale water production, reduced reliance on small-scale purification units, ability to control the availability of treated-water, improved management of the dissolved solids and hardness, and the plant configuration which allows for easy monitoring of system performance and for routine service.
RO membrane technology is a proven technology for commercial and industrial water treatment. Commercial RO membranes are utilized in a wide variety of applications, from restaurants and hotels to medical and scientific facilities.
The finished project provided Boutique International with a new facility water-treatment asset on top of its current facility infrastructure.
Customer Feedback / Testimonial
Installation was finished with special consideration for the performance of the plants, ease of access and ease of operation. The system was tested during commissioning and the operating procedures were discussed to the facility staff.
The 2000 LPH Commercial RO Plant has been installed at our facility in Gurgaon and we are pleased with the professional installation and commissioning of the RO Plant. The RO Plant is working as per our water-treatment requirement and the Technical team provided us the required support during installation, testing and handover.
In execution of this project success highlights the needs of using proper plant capacity together with proper pretreatment, reliable equipment, proper installation and technical support.
Call to Action
When it comes to selecting the best commercial RO Plant Manufacturer in Gurgaon, the decision is crucial if you have a factory, office, hotel, hospital, school, institution, warehouse or commercial facility which needs a reliable water-treatment plant.
A commercial RO system should be configured based on your specific water analysis, your daily water demand, the number of hours the system will be used, available space and the specific quality of water you want to produce—rather than just picking a capacity from a standard capacity chart.
We design, manufacture, install and commission the commercial RO plants for various water needs and operating conditions. The treatment configuration can be designed depending on the application and feed-water characteristics, if you need a 500 LPH, 1000 LPH, 2000 LPH, 3000 LPH, 5000 LPH or a customised commercial RO plant.
| Available Capacities |
| 500 LPH |
| 1000 LPH |
| 2000 LPH |
| 3000 LPH |
| 5000 LPH |
| Customised commercial RO plant |
Services offered range from requirement assessment to designing the water-treatment system, selecting the equipment, manufacturing the RO plants, commissioning and training the operators, troubleshooting and providing equipment maintenance support and replacement of consumables and membranes.
The installation of a 2000 LPH Commercial RO plant at Boutique International, Gurgaon, showcases our capability to take on commercial water-treatment projects from system design to final commissioning.
Looking for a reliable Commercial RO Plant Manufacturer in Gurgaon? Contact us today and speak about your water requirement.
Provide us with your raw-water test report and daily water demand and our technical team will be able to suggest the capacity and treatment configuration of the RO plant required for your facility.
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Conclusion
The Boutique International project did not just use the RO membrane but included all the components of a complete treatment process, such as pretreatment, fine filtration, pressure generation, membrane separation, monitoring, commissioning and operational guidance. This is significant because the performance and life of the membrane is highly dependent on the quality of the water treated and the quality of pretreatment.
The system installed has a capacity of 2000 litres per hour and enables the Boutique International‘s Gurgaon facility to have a significant treatment water production capacity with the help of installed system. Reliable long term operation is also achieved through correct installation, system commissioning and equipment arrangement which is easy to access.
If any organisation is planning to install a similar RO Plant in Gurgaon, it is advisable to choose a Commercial RO Plant Manufacturer in Gurgaon to ensure that plant capacity, water chemistry, pretreatment and operational requirements are all taken care.
A business where treated water availability is a constant requirement can turn to a professionally engineered commercial RO plant for a reliable solution that is scalable and can provide them with the water they need.
Contact Netsol Water at:
| Contact | Details |
| Phone | +91-9650608473 |
| enquiry@netsolwater.com |
