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Water treatment guides

92 practical guides on RO plants, dosing pumps, flow meters, softeners, membranes and treatment chemicals — written for the people who actually run and buy these plants.

Flow Meters 9

Rotameters, electromagnetic meters, sizing and fault finding

How to select a rotameter — sizing by flow range (LPH)Rotameter selection guide: pick the right model by flow range (LPH) and NB size. Complete Aster range chart from F100 to F60000 with prices, installation rules and common mistakes. Rotameter vs digital flow meter — which one to useDifference between a rotameter and a digital flow meter (FT-650), cost comparison, when a totaliser is worth it, and which suits your RO or industrial plant. When an electromagnetic flow meter is worth it — and when it is notHow an electromagnetic flow meter works, when it is necessary and when it is a waste of money. Size chart 25NB to 150NB, PTFE lining, prices and installation rules. How to decide the NB size of a flow meterWhat NB means, conversion to inches, choosing pipe size by flow, safe velocity limits, and what goes wrong when the NB is mismatched. Rotameter float stuck — cleaning and repair guideWhy a rotameter float sticks, floats at the top or oscillates, with a step-by-step cleaning method and how to stop it happening again. FT-650 insertion vs full bore — which type to chooseDifference between full bore and insertion type FT-650 digital flow meters, which suits which line size, costs, and the fittings an insertion type needs. 4-20mA and RS485 outputs explained — when you need themWhat 4-20mA and RS485 outputs do, the difference between them, add-on costs by instrument, and how to get data to a panel, datalogger or mobile. Flow meter reading wrong — six causes and fixesWhy a flow meter reads low, high or unsteady — installation errors, trapped air, scale, earthing — plus a bucket test to check whether the meter is actually faulty. Where to fit flow meters on an RO plantWhich lines need flow meters on an RO plant, how to calculate recovery, model selection by plant capacity, and reading flow with pressure and TDS together.

Dosing Pumps 10

Selection, dosing calculations, materials and troubleshooting

How to select a dosing pump — by LPH and pressureDosing pump selection made simple: how much LPH you actually need, what pressure rating to choose, PP or PVDF, and the full Edose range with prices. Antiscalant dosing calculation — step by stepHow much RO antiscalant to dose: from ppm to ml per hour, making up the solution, setting pump stroke, and the mistakes that waste chemical. PVDF vs PP dosing pump — which material for which chemicalHow to choose dosing pump material: when PP is adequate, when PVDF is essential, what PTFE adds, plus a chemical compatibility chart and prices. Dosing pump will not prime — seven fixesPump running but no chemical going in? Seven causes of a dosing pump failing to prime, with the fix for each, and how to stop it recurring. Edose NEO vs NEO PRO vs MAX — which model for which plantComplete comparison of the Edose dosing pump range: basic, NEO, NEO PRO, HP and MAX. Features, prices and which model suits which plant. Why a level switch matters on a dosing pumpWhat a dosing tank level switch does, why it protects both the pump and your membrane, what it costs, and how to set it correctly. Motorised vs solenoid dosing pump — which to chooseDifference between solenoid and motorised dosing pumps, which capacity range each covers, power consumption, maintenance and full price comparison. How to size a dosing tank — calculation and chartWhat size dosing tank to use, how many days of solution to make up, LLDPE vessel options, and the rules for installing a dosing tank correctly. pH correction dosing — designing an acid or alkali systemHow to build a pH correction system: pump, sensor and controller options, target pH by application, ETP considerations, safety and budget. Dosing accessories — injection nozzle, foot valve and level switchWhat each dosing pump accessory does, why the injection nozzle and foot valve matter, level switch protection, and prices.

Controllers & Panels 8

RO panels, ASTERO controllers, protection and automation

How to select a control panel for an RO plantSelecting an RO control panel by pump HP and phase, what the model numbers mean, the full Astero range with prices, and the mistakes to avoid. Astero 11NXT vs 13NXT vs 33NXT — full comparisonComparison of Astero 11NXT, 13NXT and 33NXT panels: phase, HP capacity, prices, RM and BWS versions, and which suits your RO plant. Pump keeps tripping — what to checkWhy an RO plant pump trips repeatedly: dry run, overload, voltage, phase failure, choked filter — with a step-by-step diagnosis for each. Dry run protection — what it is and why it mattersWhat dry running does to a pump, three ways to protect against it with level and pressure switches, correct settings, and what it costs. When you need a star delta panel — for 15HP and aboveWhat a star delta starter does, how it differs from DOL, at what motor rating it becomes necessary, and why large motors should not run without one. Remote monitoring (RM) panels — benefits and costHow an Astero RM panel puts plant data on your mobile, what it costs including annual hosting, and which plants genuinely benefit from it. UF plant controller vs RO controller — what is differentWhy UF and RO controllers are different, backwash sequencing explained, the Astero UF NG and UF NXT models, and which suits your plant. How to select an ETP or STP automation panelWhat an ETP or STP panel must handle, what working plus standby means, when an energy meter version is worth it, and indicative costs by plant size.

Instruments 11

TDS, pH, ORP, chlorine, turbidity and DO monitoring

TDS meter vs conductivity meter — what is the differenceThe real difference between TDS and conductivity, the conversion factor, which meter suits which application, and the Aster range with prices. How long does a pH sensor last, and when to replace itHow long a pH sensor lasts, the signs it is failing, how to extend its life, when only the sensor needs changing, and prices for each type. pH controller PO 650 — installation and calibrationInstalling an Aster PO 650 pH controller: where to fit the sensor, two-point calibration, dead band settings, relay wiring and troubleshooting. What ORP is, and why it is measured in cooling towersORP explained in plain terms: what the mV reading means, how it relates to chlorine, why it is used in cooling towers and pools, and the Aster range. When to fit a chlorine meter — free residual chlorine guideWhat free residual chlorine is, target levels by application, when an online chlorine meter is necessary, and when a test kit or ORP is enough. Turbidity and NTU — what level is acceptableWhat turbidity means, NTU limits by application, why SDI matters more than turbidity for RO, and when an online turbidity meter is justified. Using a DO meter in an ETP — and cutting the power billWhat dissolved oxygen should be in an aeration tank, how DO monitoring reduces blower electricity cost, sensor care, and cheaper alternatives. Automatic RO permeate diversion using a conductivity controllerHow to divert RO permeate automatically when TDS rises, using a CT 650 controller and solenoid valve, with setpoints, wiring and the ROMATIC option. How to calibrate sensors on site — step by stepComplete calibration method for pH, conductivity, ORP, DO and chlorine sensors, how often to do it, buffer handling and the common mistakes. Why an ETP needs special sensorsWhy standard sensors fail in ETP water, what is different about an ETP grade sensor, a two-year cost comparison, and where standard sensors still work. Where to fit pressure gauges — the cheapest diagnostics you can buyWhere pressure gauges belong on an RO or filtration plant, how to read pressure drop, choosing range and glycerine filled types, and prices.

Cartridge Filters & Housings 9

Micron selection, filter types, housings and leaks

What micron cartridge filter should you useWhat micron rating means, what to use ahead of an RO plant, correct multi-stage sequence, and what goes wrong with the wrong micron. PP spun vs string wound vs pleated — which is betterComparison of the three cartridge filter types, what each suits, annual cost analysis, and why material affects life rather than water quality. When should a cartridge filter be changedHow to judge cartridge replacement by pressure drop rather than guesswork, typical intervals, what the colour tells you, and the correct changing procedure. 10 inch, 20 inch or jumbo — cartridge housing size guideChoosing a cartridge housing: sizes and flow capacity, PP versus SS options, NB connections, bag filter housings and prices. When a bag filter is better than a cartridgeBag filter and cartridge compared: dirt holding capacity, cost analysis, which water suits each, and how to fit a bag correctly. Absolute vs nominal micron rating — the real differenceWhat nominal and absolute micron ratings actually mean, which applications need which, and how to tell an absolute filter from a nominal one. Cartridge housing leaking — O-ring and thread problemsWhy a cartridge housing leaks, how to fix an O-ring properly, thread and over-tightening problems, and when the housing itself must be replaced. When an SS304 housing is necessary — upgrading from PPPP versus SS304 cartridge housings, pressure and temperature limits, a ten year cost comparison, and SS304 versus SS316. Disc filter vs screen filter — which one to chooseDifference between Y-type disc and screen filters, which suits which water, size chart from three quarter inch to three inch, and cleaning method.

FRP Vessels 6

Sizing, media loading, distribution systems and faults

FRP vessel size chart — 0844 to 3072 with capacitiesComplete FRP vessel size chart with resin capacity, what the four digit code means, how to pick the right size, and flow rates for each. How much media to load in a vessel — the freeboard ruleHow much resin, sand or carbon a vessel should hold, why freeboard matters, correct gravel layering, and the loading procedure step by step. Top mount vs side mount vessel — which to chooseDifference between top mount and side mount FRP vessels, which suits which size, headroom requirements, and how it affects valve selection. Distribution systems — choosing hub and lateral assembliesWhat a distribution system does inside a vessel, top distributor and bottom lateral options, how to choose by vessel size and flow, with prices. FRP vs MS vessel — which should you chooseFRP and mild steel vessels compared: corrosion, service life, weight, cost over ten years, and where each is genuinely the better choice. FRP vessel leaking or bulging — causes and what to doWhy an FRP vessel leaks at the thread or bulges, how over-pressure and vacuum cause damage, which faults are repairable, and how to prevent them.

Multiport Valves 6

MPV selection, codes, automation and backwash problems

How to select a multiport valve — filter or softener, top or sideMultiport valve selection by duty, mounting and size, the difference between filter and softener valves, and the complete range with prices. Understanding MPV codes — what 0525, 1240 and 3565 meanHow multiport valve model codes work, what each part means, decoding FTM, STM, FSM and SSM, and a quick reference table. Manual vs automatic multiport valve — which is worth itManual and automatic multiport valves compared: what automation actually saves, the price difference, and when each is the right choice. Multiport valve backwash not working — troubleshootingWhy a multiport valve backwash fails: low flow, worn seals, blocked drain, media in the valve, with diagnosis and fixes for each. Brine director and brine switch — what they doWhat a brine director does in a softener brine tank, why a brine switch matters on automatic valves, sizing, and common brine system problems. EVOLVE multiport valves — what is differentWhat the EVOLVE automatic multiport valve series offers, the models and prices, what it needs to run, and when it is the right choice.

RO & UF Membranes 6

Replacement, sizing, housings, cleaning and life

When to replace an RO membrane — five clear signsHow to tell a membrane is finished rather than fouled: falling permeate, rising TDS, pressure changes, and how to read them together. 4040 vs 8040 RO membranes — sizing and outputWhat membrane size codes mean, typical output per element, how many elements a plant needs, and choosing between 4040 and 8040. RO membrane housings — pressure rating and selectionChoosing an RO membrane housing: pressure rating, material, port arrangement, elements per vessel, and O-ring and brine seal maintenance. How to extend RO membrane life — seven practical stepsPractical steps that extend RO membrane life: pre-treatment, antiscalant, dechlorination, correct recovery, monitoring and shutdown practice. UF vs RO membranes — when to use whichDifference between ultrafiltration and reverse osmosis, what each removes, operating pressure and cost, and when UF is used ahead of RO. Membrane CIP cleaning — step by step procedureWhen and how to CIP clean an RO membrane: choosing acidic or alkaline cleaner, the full procedure, safety, and how to judge the result.

ZeroScale Chemicals 8

Antiscalant, dechlorination, boiler and cooling tower treatment

What RO antiscalant does and how much to doseHow antiscalant prevents membrane scaling, typical dose rates by feed TDS, what happens without it, and how to check it is actually working. CIP cleaners — acidic or alkaline, and when to use eachHow to choose between acidic and alkaline membrane cleaners, identifying the type of fouling, the correct sequence, and safety precautions. SMBS dechlorination — why it matters and how much to doseWhy chlorine must be removed before an RO membrane, how SMBS works, the dose ratio, and how to verify chlorine is actually at zero. Boiler oxygen scavenger — why it is essentialHow dissolved oxygen corrodes boiler systems, how a scavenger works, dosing considerations, and what to monitor alongside it. Boiler scale — why it forms and how to prevent itHow scale forms in boilers, what it costs in fuel, the three lines of defence, and how blowdown and conductivity control fit together. Cooling tower biocide — oxidising vs non-oxidisingWhy cooling towers grow bacteria, the difference between oxidising and non-oxidising biocides, why they are alternated, and ORP based dosing. Controlling algae in a cooling towerWhy algae grows in cooling towers, the problems it causes, chemical and physical control measures, and how to prevent recurrence. Condensate line corrosion — causes and preventionWhy condensate lines corrode from carbon dioxide and oxygen, how to recognise it, chemical treatment options, and why condensate recovery is worth protecting.

Water Softeners 6

Sizing, regeneration, salt use and troubleshooting

Water softener sizing — calculating resin from hardnessHow to size a water softener: resin volume from hardness and consumption, vessel selection, service flow limits and a worked example. Softener regeneration — the complete process explainedEvery step of softener regeneration explained, how long each takes, what goes wrong at each stage, and how to check it worked. How much salt does a softener use — and how to reduce itHow much salt a softener needs per regeneration, monthly cost by vessel size, what salt quality to use, and practical ways to reduce consumption. Why softened water feels slippery — and is it a problemWhy soft water feels slippery with soap, whether it is a fault, how much sodium is added, and when a softener is not the right treatment. What hard water actually costs you — seven real effectsWhat hard water does to geysers, boilers, pipes, laundry and RO membranes, with the actual cost of each and when softening pays for itself. Softener not removing hardness — troubleshooting guideWhy a softener stops removing hardness: brine problems, channelling, fouled resin, wrong settings — with diagnosis and fixes for each.

Plants — RO, DM, ETP, STP, UF 9

Plant design, capacity, recovery and operation

How to size an RO plant — capacity, recovery and feed flowHow to work out RO plant capacity from daily demand, what recovery to use at different feed TDS, feed pump sizing and a full worked example. RO plant pre-treatment — designing it correctlyWhich pre-treatment stages an RO plant needs based on feed water analysis, the correct order, sizing, and what each stage protects against. RO recovery and reject water — how much is normalWhat RO recovery means, safe recovery by feed TDS, why higher recovery damages membranes, and practical ways to use the reject water. DM plant vs RO plant — which do you needHow a DM plant differs from RO, what water quality each produces, running costs compared, and why the two are often combined. RO plant output has dropped — finding the causeA systematic method for diagnosing reduced RO output: reading flow, pressure and TDS together, checking upstream first, and what each pattern means. ETP stages explained — from raw effluent to dischargeEvery stage of an effluent treatment plant, what happens at each, the instruments needed, and where plants most commonly fail. STP technologies — MBBR, SBR and conventional comparedHow MBBR, SBR and conventional activated sludge STPs differ, space and power requirements, which suits which application, and monitoring needs. ETP discharge monitoring — what to measure and recordWhat parameters need monitoring at an ETP discharge point, which instruments provide continuous records, telemetry, and how to keep compliance records. UF plant backwash — cycle timing and operationHow a UF plant backwash cycle works, typical timings, CEB chemical cleaning, controller options, and troubleshooting flux decline.

Buying & Maintenance 4

Water testing, plant purchase, upkeep and common errors

What water tests you actually need before buying a plantWhich water parameters to test before specifying treatment, what each result means, which tests you can do yourself, and typical kit costs. Water plant maintenance — a practical scheduleDaily, weekly, monthly and annual maintenance tasks for an RO and softener plant, what records to keep, and what spares to hold. Before buying a water treatment plant — what to askWhat to establish before ordering a plant, the questions to ask any supplier, what should be in the quotation, and common ways buyers get caught out. Ten mistakes that cost water treatment plants the mostThe ten most expensive and most common errors we see on water treatment plants, why each happens, and what it costs to prevent.

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