Manual de Lecho Mixto

8/10/2019 Manual de Lecho Mixto

1/120

VPT Series

Two Bed Deionizer

_________________Model Number

_________________Serial Number

Operation &Maintenance Manual

68/S41TX-03XXX

Rev. 0March, 2003

USFilter10 Technology DriveLowell, MA 01851

Technical Support: 800-875-7873 ext. 5000Telephone: 978-934-9349Fax: 978-458-6922

Email: [email protected]


2/120

TABLE OF CONTENTS

FOR

VP SERIES TWO-BED DEIONIZER

SECTION DESCRIPTION PAGE

PREFACE PAGES

Disclaimer Statement................................................................................... i

Proprietary Rights Statement....................................................................... i

Manual Users Guide .................................................................................. ii

Equipment Support .................................................................................... iii

1.0 INTRODUCTION

1.1 General System Description ................................................................... 1-1

1.2 System Design Specifications................................................................. 1-4

1.3 Glossary of Terminology ......................................................................... 1-5

2.0 SAFETY PRECAUTIONS

2.1 General Safety Guidelines ...................................................................... 2-1

2.2 Specific Safety Precautions .................................................................... 2-5

2.3 Material Safety Data Sheets (MSDS's)................................................. 2-10

3.0 PREPARATION AND STARTUP

3.1 Equipment Storage and Installation ........................................................ 3-1

3.2 Initial Equipment Receipt and Inspection................................................ 3-2

3.3 Storage of Unassembled Components ..................................................... 3-4

3.4 Equipment Installation Guidelines........................................................... 3-7

3.5 Installation of Utilities and Other Peripheral Equipment ......................3-11

3.6 System Preparation Checklist ................................................................ 3-13

3.7 Inspection of Factory-Installed Distribution Laterals............................ 3-14

3.8 Equipment Flush Procedures ................................................................. 3-16

3.9 Pressure Testing..................................................................................... 3-18

3.10 Vessel Loading ...................................................................................... 3-22

3.11 Startup Procedures ................................................................................. 3-25

3.12 Deionizer Data Form.............................................................................. 3-27


3/120

TABLE OF CONTENTS

FOR

VP SERIES TWO-BED DEIONIZER

SECTION DESCRIPTION PAGE

4.0 OPERATION

4.1 Theory of Operation................................................................................. 4-1

4.2 Process Control Document (Control Write-Up) ...................................... 4-1

Control Overview

Two Bed Operation

Alarms

Data Access Tool

Valve Sequence

Instrumentation

External Interlocks

Duplex Operation

4.3 Regenerant Make-Up Procedures ............................................................ 4-14.4 Backwash Flow temperature Correction ................................................. 4-4

4.5 Special Operating Procedures.................................................................. 4-5

4.6 Process and Instrumentation Diagram (P & ID)...................................... 4-5

5.0 SAMPLING AND TESTING

5.1 Taking Samples for Analysis.................................................................. 5-2

5.2 Procedure for Checking Specific Gravity................................................ 5-6

6.0 MAINTENANCE AND TROUBLESHOOTING

6.1 Maintenance General ............................................................................... 6-1

6.2 Component Maintenance ......................................................................... 6-4

6.3 Troubleshooting ....................................................................................... 6-7

7.0 SHUTDOWN AND STORAGE

7.1 Shutdown on Power Loss........................................................................7-1

7.2 Unloading VP Series Deionizers ............................................................ 7-4

7.3 Storage ..................................................................................................... 7-5

8.0 PARTS LISTS AND DRAWINGS

8.1 Equipment List......................................................................................... 8-1

8.2 Recommended Spare Parts List .............................................................. 8-2

8.3 Drawings..................................................................................................8-3

9.0 VENDOR LITERATURE

9.1 Vendor Literature Section........................................................................ 9-1


4/120

i

DISCLAIMER STATEMENT

The VPT Series Two Bed Deionizer Operation and Maintenance (O&M) manual should be used with

the vendor literature in Section 9.0 of this manual. Both sources should provide the most current and

complete information to meet your operating and/or service requirements as available at the time of

publication. However, USFilter assumes no responsibility for the technical content of the vendor

literature in Section 9.0 of this manual.

The information in these manuals may not cover all operating details or variations, or provide for all

conditions concerning installation, operation and maintenance. Should questions arise which are not

answered specifically in this manual, contact the USFilter Service Department at the toll free number on

this manuals front cover.

USFilter reserves the right to make engineering refinements that may not be reflected in these manuals.

The material in these manuals is for informational purposes and is subject to change without notice.

PROPRIETARY RIGHTS STATEMENT

This manual discloses information in which USFilter has proprietary rights. Neither receipt nor

possession of this manual confers or transfers any right to the client, and by its retention hereof, the

client acknowledges that it will not reproduce or cause to be reproduced, in whole or in part, any such

information except by written permission from USFilter. The client shall have the right to use anddisclose to its employees the information contained herein for the purpose of operating and maintaining

the USFilter equipment, and for no other purpose.

In the event that this manuals content is altered, or section/items are omitted during a partial or

complete reproduction, and those altered instructions or definitions within the reproduction result in

personal injury to those who follow them, then the burden of responsibility for personal injury falls

solely on the party who affects the reproduction.


5/120

ii

MANUAL USERS GUIDE

This O&M manual describes the procedures necessary to install, operate, and maintain your USFilter

liquid treatment system. Please read this manual carefully before installing and operating your

equipment. The equipment warranty may be voided if installation or operation instructions are not

followed correctly.

This manual has been formatted for ease of use, combining the instruction for all USFilter subsystems

into one comprehensive manual. Literature supplied with purchased components being used on USFilter

equipment is being provided in Section 9.0 of this manual.

The nine tabbed sections cover general information applicable to all pieces of equipment in the system.

The table of contents for these sections is located at the front of the manual. The pages within each

section are numbered [section #]-[page #] with the page numbers starting at 1 and incrementing

sequentially.

NOTE: Page numbering will skip over any special documents and continue on the page

following the document. Special documents will be noted with an introduction

statement that is listed in the table of contents.

Warnings, Cautions, and Notes are used to attract attention to essential or critical information in a manual.

Warnings and Cautions will appear before the text associated with them, and notes can appear either before

or after associated text.

Warnings indicate condition, practices, or procedures that must be observed

to avoid personal injury or fatalities.

Cautions indicate a situation that may cause damage or destruction of

equipment, or may pose a long term health hazard.

NOTE: Notes are used to add information, state exceptions, and point out areas that may

be of greater interest or importance.

WARNING

CAUTION


6/120

iii

EQUIPMENT SUPPORT

USFilter continually strives to provide safe, efficient, trouble-free equipment using the optimum

technology for your application. If problems should develop, USFilters worldwide network of technical

support will be available to provide assistance. For service, sales, parts, or additional manual copies, call

your area sales representative or the telephone numbers provided on this manuals front cover.


7/120


8/120

VP TWO-BED DEIONIZER Page 1-2

INTRODUCTION Rev. 0

1.1.1 Mechanical Description

Two pressure vessels are piped in series (left to right orientation). The first vessel

contains cation resin shipped in the sodium form. The second vessel contains anion resin

shipped in the chloride form. The two-bed system must be regenerated before being put

into service with 30% HCl (cation) and 50% NaOH (anion).

The piping is constructed of Schedule 80 PVC using socket-welded and flanged fittings.

Complete piping from the inlet of the cation to the outlet of the anion is provided. Re-

assembly of the interconnecting piping is required, unless the skid-mounted option is

selected. All automatic valves are spring-to-close, except the backwash, rinse outlets,

and dilution water to the eductors. These are actuated using dry, oil-free, instrument air.

Four structural steel legs, designed for seismic zone 2A (standard) or seismic zone 4

(optional) support each vessel.

The skid-mounting option provides a structural steel open frame secured to both vessels,

eliminating the need for re-assembly of the interconnecting piping. The skid optionsconsist of frames designed for seismic zone 2A (standard) or seismic zone 4 (optional).

All external steel surfaces are sandblasted and coated with durable epoxy paint. The

interiors of the vessels are sandblasted and lined with a chemical and abrasion-resistant

vinyl ester coating. Baked PVC linings are available as an option.

Regenerant eductors are supplied in the face piping of each vessel and will require the

customer to supply concentrated chemicals within the immediate vicinity of the

equipment.

1.1.2 Electrical Description

To control the operational sequences and monitor the performance of the VP Seriestwo

bed deionizer, a highly reliable solid-state programmable logic controller (PLC), flow

totalizing meter and conductivity monitor are provided. Opening and closing of the

process valves is accomplished using instrument air and solenoid pilot valves located on

the control enclosure. The flow totalizing meter and conductivity monitor is used to

initiate the regeneration sequence. Flow and conductivity meters are mounted in the

panel door for ease of viewing. Adjustment of the factory pre-set step times is easily

accomplished by using the Data Access Tool (DAT) which is provided with the

equipment and located inside of the enclosure. All electrical components are contained

within a NEMA 4 enclosure for protection from humidity, moisture and dust.1.1.3 Operational Description

The deionizer has two modes of operation, manual and automatic. In the manual mode,

operator intervention is required to start the regeneration sequence and return the unit to

service. A high conductivity alarm and a totalized gallon throughput alarm are provided

to alert the operator that regeneration is required. In the automatic mode, all functions

are performed without operator intervention.


9/120


INTRODUCTION Rev. 0

When the volume of water treated or the product water conductivity has exceeded the

pre-set values, the unit is automatically taken off-line and the regeneration sequence

begins. A low flow recirculation pump can be supplied as an option to maintain a

minimum flow rate through the deionizer during periods of low or no product water

demand while in the service mode.

Regeneration of the cation and anion vessels occurs sequentially; that is, the cation vesselis regenerated first, then the anion vessel is regenerated. Anion regeneration water is

derived from the cation vessel. The rated capacity (Kgrains) of the deionizers is based on

the anion resin volume. The regeneration sequence for each vessel consists of four steps:

backwash, chemical in, slow rinse and fast rinse.

Duplex systems will operate in an alternating or parallel fashion. In the alternating

fashion, one set of deionizers will be in the service mode while the other set of deionizers

will be in the regeneration or standby mode. This provides a continuous, uninterrupted

supply of deionized water. In the parallel mode, each deionizer operates independently

as two single units. Each of the deionizers will be provided with a PLC and solenoid

pilot valves, pre-tubed to the process valves and pre-wired to the PLC terminal strip. Theduplex alternating configuration requires wiring of the interlocks between the two

enclosures by the customer.

1.1.4 Design Parameters

The following chart details the design parameters.

Configuration: Simplex (duplex optional)

Feed Temperature: 45to 95F

Feed Pressure: 45 to 100 psigMaximum Inlet Turbidity: 5 NTU

Maximum Inlet TDS: 500 ppm as CaCO3(29.2 grains/gallons)

Cation Vessel Anion Vessel

Sizing: 8 gpm/ft2(2.5 gpm/ft

3) 8 gpm/ft

2(2.2 gpm/ft

3)

Bed Depth: 36 inches 42 inches

Freeboard:

Capacities: 20 Kgr/ft3 17 Kgr/ft3

4.5 lbs (100%) HCl/ft3 6.0 lbs (100%) HCl/ft

3Regeneration:

1.56 gallons 30% HCl/ft3

0.90 gallons 50% NaOH / ft3


10/120


INTRODUCTION Rev. 0

1.2 SYSTEM DESIGN SPECIFICATIONS

The design specifications for your U.S. Filter Two-Bed Deionizer are listed below. For

specifications of individual components used on the system, refer to the components instruction

sheets in the Vendor Literature Manual at the end of this manual.

1.2.1 Standard Specifications

Pressure Vessels:

Materials: Carbon steel, butt welded seams

Rating: 100 psig non-code (optional: ASME code & stamp)

Support: Structural steel legs, seismic zone 4 (optional: zone 2A and 4 skids)

Access Openings

16, 20, and 24 diameter Non-code: removable head w/ (2) 4 x 6 hand holes

ASME code: flanged top and bottom heads

30 through 72 diameter (1) 11 x 15 crab style

Process Connections: Pad flange

Paint 5 to 7 mil DFT epoxy (optional: 20 to 40 mil DFT baked PVC)

Lining 35 to 45 mil DFT vinyl ester (optional 60 to 80 mil DFT baked

PVC)

Distribution Systems:

Upper PVC radial flow point distributor

Lower (underdrain) PVC hub with PVC slotted laterals

Piping Systems:Process Schedule 80 PVC, socket-welded and flanged

Regenerant Schedule 80 PVC, socket-welded

Backwash Schedule 80 PVC, socket-welded & flanged with clear sight glass

Automatic Process Valves:

2 and smaller PVC bodied, EPDM diaphragm

2-1/2 and larger Cast iron butterfly, EPDM seats, Nylon-coated disk, SS trim

Actuation Air-to-open, spring-to-close, except backwash, rinse outlet and

dilution water to the eductors, which are air-to-open and air-to-close

Manual Valves:Feedwater Sample (1) PVC ball

Product Water Sample (2) PVC ball, one on each vessel

Regenerant Sample (2) PVC ball, on for each regenerant chemical

Gauge Isolation (3) PVC ball, one for each pressure gauges


11/120


INTRODUCTION Rev. 0

1.2.2 Instrumentation Specifications

Pressure:

Service Inlet Gauge (1) 2 dial, 316 stainless steel

Cation Effluent (1) 2 dial, 316 stainless steelService Outlet Gauge (1) 2 dial, 316 stainless steel

Flow:

Feedwater Sensor Signet paddlewheel flow element on inlet to cation vessel

Feedwater Monitor Red Lion digital display with rate and totalized flow mounted in

panel

Quality:

Product Conductivity Sensor Thornton 240-XXX cell in the effluent piping of the anion vessel

Product Conductivity Monitor Thornton 200 CR Digital meter mounted in panel

1.2.3 Controls Specifications

Enclosure NEMA 4 enamel painted steel

Programmable Logic Controller

(PLC)

Allen-Bradley MicroLogix 1500, 24 VDC, fixed I/O type

PLC Input/Output Allen-Bradley discrete 32 point (12 inputs, 20 outputs)

DAT Allen-Bradley

Alarm horn Edwards, NEMA 4Pushbuttons and lights Allen-Bradley

Circuit breaker Square D (panel power switch)

Warning alarms High effluent conductivity (manual mode only)

Throughput exceeded (manual mode only)

Numeric displays Red Lion, XX LED for flow rate (gpm) and total gallons

Operator interface Manual/Automatic selector switch

Alarm silence pushbutton

Regeneration illuminated pushbutton (press and hold to restart)

Service illuminated pushbutton

Solenoid pilot valves MAC, 45A, 4-way, 24 VDC, manifold-mounted on enclosure


12/120


INTRODUCTION Rev. 0

1.2.4 Interface Communications Specifications

Input 1 (by others) Dry contact closure indicates upstream water is available

Input 2 (by others) Dry, momentary contact closure parallels Service pushbutton

Output 1 (relay) Configurable to indicate regeneration or Service

1.2.5 Operating Limits

Temperature:

Maximum Feed Temperature 95F

Minimum Feed Temperature 45F

Pressure:Maximum Feed Pressure 95 psig

Minimum Feed Pressure 45 psig

Maximum Pressure Variability 5 psig (optional; inlet pressure control valve)

NOTE: If any of the operating conditions are not within the limits given, consult the factory for the

appropriate recommendation and application assistance.

1.2.6 Process Influent Guidelines

Parameter Guideline

Suspended Solids 5 NTU maximum

Total Dissolved Solids 500 ppm maximum

Alkalinity 30% of total anions

Chlorides 30% of total anions

Sodium 50% of total cations

Silica 10% of total anions

Iron + Manganese 0.3 ppm combined

Free Chlorine 0.2 ppm

Color 5 APHA units

Organics 2.0 ppm TOC as O2

NOTE: If any of the feedwater parameters are not within the limits given, consult the factory for the

appropriate recommendation and application assistance.


13/120


INTRODUCTION Rev. 0

1.2.7 Regulations and Standards

Pressure Vessels Hydrostatically tested at 1.5 times the rated pressure

Surface Preparation SSPC SP-10 for vessel interior, SSPC SP-6 for external steelsurfaces

Electrical NEMA 4, (optional UL listed)

Seismic Rating Zone 4 legs (optional: skid for zone 2A and zone 4)

Piping Hydro tested to 100 psig minimum

1.2.8 Documentation Package

Documents Storage, installation and operating instructionsOperating sequence parameters, shipping list, and spare parts list

Drawings Process & Instrument (P&ID), General Arrangement (GA) and line

wiring

Software Factory-loaded, ladder logic supplied on disk

Quality Documents UA-1 form with ASME code vessels

1.2.9 Flow Rate Specifications (in gpm)

Diameter 016 020 024 030 036 042 048 054 060 066 072

Service (design) 10 17 24 38 54 74 97 123 153 182 220

Service (minimum) 3 4 6 10 14 19 23 31 39 47 55

Backwash Cation* 7 12 17 26 37 51 67 85 105 125 151

Backwash Anion* 3 5 7 10 15 20 27 34 42 50 61

Combined Fast

Rinse 10 17 24 38 54 74 97 123 153 185 220

* The backwash rates are based upon a flow temperature of 60F (16C).

NOTE: If the service flow rate drops below the minimum values listed, the automatic low flow

recirculation pump accessory should be selected to maintain reliable performance of the

deionization system.

The service flow rate must be limited with a rate-set valve. An unrestricted flow rate will

lower the quality of the effluent.


14/120


INTRODUCTION Rev. 0

1.2.10 Media Specifications

Diameter 016 020 024 030 036 042 048 054 060 066 072

Cation: U.S. Filter C-211: 8% cross-linked strong acid, shipped in sodium form (50 lbs/ft3)

Resin Volume (ft3) 4 6 10 15 21 28 36 46 57 69 82

Resin weight # 224 336 560 840 1176 1568 2016 2576 3192 3864 4592

Capacity (Kgrains) 80 120 200 300 420 560 720 920 1140 1380 1640

Anion: U.S. Filter A-244: strong base, Type II (gel), shipped in chloride form (44 lbs/ft3)

Resin Volume (ft3) 4.5 7 11 17 24 33 42 54 67 81 96

Resin Weight # 198 308 484 748 1056 1452 1848 2376 2948 3564 4224

Capacity (Kgrains) 77 120 190 290 410 560 715 920 1140 1380 1640

NOTE: The resin capacities listed are nominal values only. The actual operating capacity will

depend on the feed water composition and other operating conditions.

Refer to Section 7, Parts List, for media part numbers and specifications.

1.2.11 Regeneration Flow Rate Specifications (in gpm)

Diameter 016 020 024 030 036 042 048 054 060 066 072

Exhaustion Rinse 10 17 24 38 54 74 97 123 153 182 220

Backwash Cation 7 12 17 26 37 51 67 85 105 125 151

Acid In 1.7 2.5 4.2 6.3 8.8 11.8 15.1 19.3 23.9 29 34.4

Slow Rinse Cation 1.4 2.1 3.6 5.4 7.5 10.0 12.9 16.4 20.3 24.6 29.3

Fast Rinse Cation 10 17 24 38 54 74 97 123 153 182 220

Backwash Anion 2.9 4.6 6.6 10 15 20 27 34 42 50 61

Caustic In 1.7 2.7 4.2 6.5 9.2 12.6 16.0 20.6 25.6 30.9 36.7

Slow Rinse Anion 1.6 2.5 4.0 6.2 8.7 11.9 15.2 19.5 24.3 29.3 34.8

Final Rinse 10 17 24 38 54 74 97 123 153 182 220

NOTE: Refer to Section 1.2.13 for step times.

De-cationized water is used for the regeneration of the anion resin.


15/120


INTRODUCTION Rev. 0

1.2.12 Regeneration Volume Specifications (in gallons)

Diameter 016 020 024 030 036 042 048 054 060 066 072

Exhaustion Rinse 104 168 240 376 544 744 968 1232 1528 1816 2200

Backwash Cation 107 173 248 388 561 767 998 1271 1576 1873 2269

Acid In 42 63 105 158 221 294 378 483 599 725 861

Slow Rinse Cation 30 45 75 112 157 210 270 345 427 517 615

Fast Rinse Cation 62 101 144 226 326 446 581 739 917 1090 1320

Backwash Anion 43 69 99 155 224 307 399 508 630 749 908

Caustic In 77 120 189 292 413 567 722 928 1152 1392 1650

Slow Rinse Anion 34 53 84 129 182 251 319 411 509 616 730

Final Rinse 104 168 240 376 544 744 968 1232 1528 1816 2200

Totals

30% HCl 6.3 9.4 16 23 33 44 56 72 89 108 128

50% NaOH 4.2 6.6 10 16 23 31 40 51 63 76 91

Anion Regen 258 411 612 953 1363 1869 2409 3079 3819 4573 5488

Waste Water 604 961 1423 2212 3173 4331 5604 7149 8866 10593 12752

NOTE: De-cationized water is used for the regeneration of the anion resin.

1.2.13 Regeneration Sequence:

Step

Time

(minutes) LiquidExhaustion Rinse 10 Water

Backwash Cation 15 Water

Acid In 25 5% HCl

Slow Rinse Cation 21 Water Fast Rinse Cation 6 Water

Backwash Anion 15 Water

Caustic In 45 4% NaOH

Slow Rinse Anion 21 Water

Final Rinse 10 Water

Total Time 168

*Cation and anion vessels are regenerated sequentially.


16/120


INTRODUCTION Rev. 0

1.2.14 Customer Connection Specifications (in inches)

Diameter 016 020 024 030 036 042 048 054 060 066 072

Service Inlet 1 1 1 1 1 2 2 2 3 3 4

Service Outlet 1 1 1 1 1 2 2 2 3 3 4

Drain 1 1 1 1 1 2 2 2 3 3 4

Control Air

1.2.15 Utility Requirement

Diameter 016 020 024 030 036 042 048 054 060 066 072

Electrical 110 volts, 1 phase, 60 Hertz, 15 amp

Control Air 80 psig minimum, 100 psig maximum

Feedwater 45 psig minimum, 95 psig maximum

Maximum Drain(gpm)

10 16 24 38 54 74 92 123 153 185 220

Floor Drain A floor drain (in addition to waste drain) should be supplied for general purposes.

Option Items:

Low Flow

Recirc.

110 volt, 1 phase, 60 Hertz, 0.5 hp 0.75 hp

NOTE: Duplex-alternating systems must be powered from the same source.


17/120


INTRODUCTION Rev. 0

1.2.16 Physical Dimensions Specifications

Diameter 016 020 024 030 036 042 048 054 060 066 072

Side Sheet (inches) 72 72 72 72 72 72 72 72 72 72 72

Length4 8 5 4 6 0 7 0 8 0 9 0 10 0 11 0 12 0 13 0 14 0

Depth 310 40 42 411 52 55 66 610 70 78 84

Height, non-code 810 81 83 90 96 910 100 105 107 110 114

Height, ASME code

Shipping Weight

(lbs)

1,800 2,900 3,800 4,400 6,000 7,860 9,670 11,880 14,880 20,040 25,200

Crane Capacity

(lbs)

900 1,450 1,600 1,702 2,006 2,358 2,570 2,780 3,380 4,190 5,000

Oper. Weight (lbs) 2325 3,740 5,370 9,950 13,650 18,300 22,785 28,300 35,290 44,920 54,550

NOTE: Does not include operating space requirements or customer-supplied regenerant tanks.

Heights for skid-mounted units will be 4 inches greater than the heights listed.


18/120


INTRODUCTION Rev. 0

Standard Product Ordering Information:

Sample Part Number: VPT S 060 X X B P D

Configuration

S Simplex (see note)

Vessel Size

016 16 x 72

020 20 x 72

024 24 x 72

030 30 x 72

036 36 x 72

042 42 x 72

048 48 x 72

054 54 x 72

060 60 x 72

066 66 x 72

072 72 x 72

Vessel Rating

X 100 psig non-code

A 100 psig ASME code

Vessel Support

X Legs, seismic zone 4

Y Skid, seismic zone 2A

Z Skid, seismic zone 4

Lining & Paint

B PVC / PVC

Controls

P Solid state PLC

Control Rating

D NEMA 4 and UL label

Note: Duplex units should be ordered as two (2) simplex units.


19/120


INTRODUCTION Rev. 0

Accessories Ordering Information:

Sample Part Number: VP Z 060 LFR

Reserved

Z Accessory

Size Code

Size Codes

Diam. LFR TRP PRV Obsolete PRV Size Codes

16 016 100 075S 100

20 020 100 075D 100

24 024 100 100D 100

30 030 125 125S 125

36 036 150 125D 150

42 042 200 200S 200

48 048 200 200D 200

54 054 250 200D 25060 060 300 250S 300

66 066 300 250D 300

72 072 400 300S 400

Accessory

LFR Low flow recirculation pump

TRP Resin trap

PRV Pressure reducing regulator

Note: Accessories must be ordered as separate line items.


20/120


INTRODUCTION Rev. 0

Standard Options Available:

Ordering Information: Description of Option:

Specify option code A in

Vessel Rating placeholder.

100-psig ASME code stamped vessel. This option provides pressure vessels

designed and manufactured according to strict ASME code standards and are

supplied with a code stamp permanently affixed to the pressure vessels.Specify Y in the Vessel

Support placeholder.

Seismic zone 2A skid. This option provides a structural steel, open frame skid

underneath the cation and anion vessels designed in accordance to seismic zone 2A,

for ease of shipment and installation. The piping between the cation and anion

vessels is shipped intact.

Specify Z in the Vessel

Support placeholder.

Seismic zone 4 skid. This option provides a structural steel, open frame skid

underneath the cation and anion vessels designed in accordance to seismic zone 4,

for ease of shipment and installation. The piping between the cation and anion

vessels is shipped intact.

* Refer to the Standard Product Ordering Information for building the part number based on the options youhave chosen.

Standard Accessories Available:

Ordering Information: Description of Accessory:

Size Code Enter the vessel diameter for the low flow recirculation (LFR) accessory, e.g., a 60

diameter unit would have a size code of 060.

Enter the pipe size for the resin trap (TRP) and inlet pressure reducing regulator

(PRV). The pipe size code is listed in the Accessories Ordering Information for

each diameter unit, e.g., a 60 diameter unit has 3 piping and the pipe size code is

300.

Specify LFR in the

Accessory placeholder.

Automatic low flow recirculation pump. This accessory provides a recirculation

pump that automatically takes the effluent service water and directs it to the inlet

(bypassing the inlet flow meter) when the flow rate drops below the minimum

specified flow rate. The pump assembly is pre-wired to a junction box and shipped

loose. Customer will be required to provide the wiring between the control

enclosure and the junction box as well as piping from the pump assembly to the

deionizer.

Specify TRP in the

Accessory placeholder.

Effluent resin trap. This option provides a PVC slotted strainer in the effluent

piping of the anion vessel to prevent a catastrophic loss of resin to downstream

processes. The strainer is housed in a clear PVC sight glass to permit visual

inspection. The resin trap is the same size as the service effluent piping on the

deionizer.

Specify PRV in the

Accessory placeholder

Pressure reducing regulator. This option provides a self-contained pressure-

reducing regulator on the inlet of the cation vessel to control fluctuations in

feedwater pressure +/- 5 psig. The pressure-reducing regulator is the same or

smaller size than the inlet piping of the deionizer and will require the customer to

provide reducing fittings if required.

* Refer to the Accessories Ordering Information for specifying the accessories. Each accessory item must beordered as a separate line item.


21/120


INTRODUCTION Rev. 0

1.3 GLOSSARY OF TERMINOLOGY

NOTE: The following terms are defined as they relate to the liquid-treatment industry. Many

terms refer to processes, items or equipment not part of this order.

1.3.1 Terminology Common to All Systems

This section contains terms and definitions that are common to all liquid-treatment

systems.

Alkalinity: An expression of the total basic anions (hydroxyl groups) present in a solution. It

also represents, particularly in water analysis, the bicarbonate, carbonate, and

occasionally, the borate, silicate, and phosphate salts which will react with water

to produce the hydroxyl groups.

Anion: A negatively-charged particle or ion.

Bicarbonate

Alkalinity: The presence in a solution of hydroxyl (OH-) ions resulting from the hydrolysis of

carbonates or bicarbonates. When these salts react with water, a strong base and a

weak acid are produced, and the solution is alkaline.

Calcium Carbonate

Equivalent: This is the value obtained when salts are calculated in terms of equivalent

quantities of calcium carbonate; a convenient method of reducing all salts to a

common basis for comparison.

PPM as CaC03=ION (PPM as such) X Equivalent WT of CaCO3Equivalent WT of Ion

Carbonate Hardness: That hardness in a water caused by bicarbonates and carbonates of calcium and

magnesium. If alkalinity exceeds total hardness, all hardness is carbonate

hardness; if hardness exceeds alkalinity, the carbonate hardness equals the

alkalinity.

Cation: A positively-charged particle or ion.

Cavitation: The phenomenon which occurs in a pump where there is insufficient NPSH (Net

Positive Suction Head) available. The pressure of the liquid is reduced to a valueequal to or below its vapor pressure and small vapor bubbles or pockets begin to

form. As these vapor bubbles move along the impeller vanes to a higher pressure

area, they rapidly collapse. The collapse, or "implosion" is so rapid that it may be

heard as a rumbling noise, as if pumping gravel. May result in reduced capacity,

erratic power consumption, vibration, and mechanical damage.

Colloids: Matter of very fine particle size, usually in the range of 10-5

to 10-7

cm. in


22/120


23/120


INTRODUCTION Rev. 0

Grain per Gallon: An expression of concentration of material in solution. One grain per gallon is

equivalent to 17.12 parts per million.

Gram-Milli

-equivalents: The equivalent weight in grams, divided by 1000.

Hardness: The scale-forming and lather-inhibiting qualities which water, high in calcium

and magnesium ions, possesses. Temporary hardness, caused by the presence of

magnesium of calcium bicarbonate, is so called because it may be removed by

boiling the water to convert the bicarbonates to the insoluble carbonates. Calcium

sulfate, magnesium sulfate, and the chlorides of these two metals cause permanent

hardness.

Hardness as

Calcium Carbonate: The expression ascribed to the value obtained when the hardness forming salts are

calculated in terms of equivalent quantities of calcium carbonate; a convenient

method of reducing all salts to a common basis for comparison.

Header: A main or common piping line.

Headloss: The reduction in liquid pressure associated with the passage of a solution through

a system; a measure of the resistance of a system or component to the flow of the

liquid passing through it.

Hydroxyl: The term used to describe the anionic radical (OH-) which is responsible for the

alkalinity of a solution.

Indicators: Substances which change from one color to another when the hydrogen-ionconcentration reaches a certain value, different for each indicator.

Influent: The solution which enters a system unit.

Ion Any particle of less than colloidal size possessing either positive or negative

electric charge.

Ionization: The dissociation of molecules into charged particles.

Ionization

Constant: An expression in absolute units of the extent of dissociation into ions of achemical compound in solution.

Kilograin: A unit of weight; one thousand grains. There are seven kilograins per pound.

Mineral: A natural inorganic substance having a definite chemical composition and

structure.


24/120


INTRODUCTION Rev. 0

Mole: Mass numerically equal to the molecular weight. It is most frequently expressed

as the gram molecular weight, i.e., as the weight of one mole expressed in grams.

Molecule: The smallest unit quantity of matter which can exist by itself and retain all the

properties of the original substance.

Negative Charge: The electrical potential which an atom acquires when it gains one or more

electrons; a characteristic of an anion.

Noncarbonate

Hardness: Hardness in water caused by chlorides, sulfates, and nitrates of calcium and

magnesium.

Orifice: An opening through which a fluid can pass; a restriction placed in a pipe to

provide a means to measure flow.

pK: An expression of the extent of dissociation of an electrolyte; the negativelogarithm of the ionization constant of a compound.

pOH: An expression of the alkalinity of a solution; the negative logarithm of the

hydroxyl ion concentration.

Positive Charge: The electrical potential acquired by an atom which has lost one or more electrons;

a characteristic of a cation.

Precipitate: The amount of a substance dissolved in a solution that exceeds the solubility of

that substance and, therefore, comes out of solution.

Prefilter: A filter placed before and in series with some other type of liquid-treatment

equipment.

Productivity: The measurement of rated output, expressed in gallons/24 hour day under a given

temperature, pressure and salinity (Product Flow).

Purity: The percentage of desirable vs. undesirable components on a weight basis per unit

volume of sample.

Raw Water: Untreated water from wells or from surface sources.

Recovery: The quantity of a given component by weight in the product stream vs. the

amount of that specific component in the feed.

Salinity: The presence of soluble minerals in water.

Scale: The precipitate that forms on surfaces in contact with water as the result of a

physical or chemical change.


25/120


26/120


INTRODUCTION Rev. 0

removal of all charged constituents or ionizable salts (both inorganic and organic)

from solution.

Demineralization: See de-ashing.

Distribution: The internal piping (liquid inlets and outlets) of an ion-exchange vessel.

Double DishBottom: A concave plate inside a vessel that blocks off the bottom head (shell). Used to

eliminate problems with gravel or quartz support beds (see "support media").

Downflow: Conventional direction of solutions to be processed in ion- exchange column

operation, i.e., in at the top, out at the bottom of the column.

Exchange Velocity: The rate with which an ion is displaced from an exchanger in favor of another.

False Bottom: A flat plate inside a vessel that blocks off the bottom head (shell). Used to

eliminate problems with gravel or quartz support beds (see "support media").

Fines: Extremely small particles of ion-exchange materials.

Freeboard: The space provided above the resin bed in an ion-exchange column to allow for

expansion of the bed during backwashing.

Greensand: Naturally-occurring materials, composed primarily of complex silicates, which

possess ion-exchange properties.

Hydraulic

Classification: The rearrangement of resin particles in an ion-exchange unit. As the backwashwater flows up through the resin bed, the particles are placed in a mobile

condition wherein the larger particles settle and the smaller particles rise to the

top of the bed.

Hydrogen Cycle: A complete course of cation-exchange operation in which the adsorbent is

employed in the hydrogen or free-acid form.

InterfaceCollector: The lower intermediate distribution of a mixed-bed vessel. Used as a drain during

regeneration.


27/120


INTRODUCTION Rev. 0

Lateral: One of the individual drilled pipes that branch out from the internal vessel

distribution headers. Used as an entry or exit point for process fluids.

Media: The material (resin, carbon, quartz) that is used in a fluid-treatment vessel.

Mixed-Bed: An ion-exchange vessel containing a mixture of cation and anion resin (in a single

bed).

Physical

Stability The quality which an ion-exchange resin must possess to resist changes that might

be caused by attrition, high temperatures, and other physical conditions.

Polisher: An ion-exchange vessel, especially a mixed bed, placed after a primary exchange

unit to remove any remaining unwanted ions.

Quartz: A hard mineral. Graded quartz is used as a support media in some liquid-

treatment applications.

Regenerant: The solution used to restore the activity of an ion exchanger. Acids are employed

to restore a cation exchanger to its hydrogen form. Brine solutions may be used

to convert the cation exchanger to the sodium form. The anion exchanger may be

rejuvenated by treatment with an alkaline solution.

Regeneration: The process by which a system is conditioned to ready it for another service

cycle.

Reverse

Deionization: The use of an anion-exchange unit and a cation-exchange unit (in that order) toremove all ions from solution.

Rinse: The final step in a unit regeneration, in which water is flushed through the unit

until the effluent quality is proper.

Riser: The distribution (internal piping) pipe that carries a process liquid to or away

from the distribution headers.

Salt Splitting: The act of separating cations from anions in a process feed stream. Usually done

with ion-exchange resin.

Softening: The removal of hardness - calcium and magnesium - from water.


28/120


29/120


INTRODUCTION Rev. 0

Flocculation: The process of agglomerating coagulated particles into precipitating flocs, usually

of a gelatinous nature.

Neutralization: The act of adding acid to an alkaline effluent or alkali to an acidic effluent

to make the effluent pH neutral (7.0 pH).

pH: An expression of the acidity of a solution; the negative logarithm of the hydrogen

ion concentration (pH 1 very acidic; pH 14, very basic; pH 7, neutral).

Polyelectrolyte: Water soluble polymers containing ionizable groups as part of their structure;

often useful in causing agglomeration of fine suspended solids.

Regenerant: The solution used to restore the activity of an ion exchanger. Acids are employed

to restore a cation exchanger to its hydrogen form. Brine solutions may be used

to convert the cation exchanger to the sodium form. The anion exchanger may be

rejuvenated by treatment with an alkaline solution.

Sedimentation: Gravitational settling of solid particles in a liquid system.

Specific Gravity: The ratio of the mass of a body to the mass of an equal volume of water at 4oC or

other specified temperature. Dimension - unity.


30/120


SAFETY PRECAUTIONS Rev. 0

WARNING

2.0 SAFETY PRECAUTIONS

This section contains general safety guidelines that workers must follow when installing, operating, and

maintaining U.S. Filter equipment.

This section must be read and understood prior to system startup. The guidelines listed here must befollowed at all times to prevent worker injury and equipment damage.

2.1 GENERAL SAFETY GUIDELINES

This subsection contains the safety precautions that are common to all U.S. Filter equipment.

2.1.1 Operator Training

Equipment operators must be trained in the operation of the equipment and in the proper

handling of any hazardous materials or chemicals. Only experienced operators who havestudied this entire manual should be allowed to operate the equipment.

2.1.2 First-Aid Equipment

First-aid equipment must be available in all areas. This equipment must consist of items

needed to treat most common injuries and the items required by the Material Safety Data

Sheets (MSDS's) for the hazardous chemicals and materials used by your system (see

section 2.3).

2.1.3 Equipment Access

Workers must use caution when accessing the equipment. All measures must be taken to

prevent falls and other accidents when equipment is being installed or serviced.

Use extreme caution when working around liquid-treatment equipment. Valve handles,

sample pipes, and other protruding components can cause severe injury to body parts that

strike them. Workers should wear hard hats and safety glasses and should move

cautiously when working under piping and around the equipment.

Climbing on piping can cause worker injury or equipment damage due to falls and equipmenttipping.

Never climb on piping to reach equipment or components.

If equipment to be installed or serviced is above an operator's normal reach, use safe,

approved ladders or lifting devices to reach the required area.


31/120


32/120



WARNING

WARNING

WARNING

CAUTION

2.1.7 Electricity

Electricity can shock, injure, or cause death.

Always disconnect and lock out electrical power for panels or components

before performing repairs or service.

Operators and workers must use caution when working with motors, control panels, and

other electrical components. These components must be properly wired and grounded,

and should not be allowed to come in contact with process fluids or other liquids.

Electrical control panels and instruments must be properly grounded.

2.1.8 Temperatures

High temperatures can cause severe burns to exposed skin.

Wear gloves and protective clothing when handling components that

generate high temperatures.

Operators and workers must use caution when working with processes (steam cleaning)

or components (heat exchangers, motors, pumps etc.) that involve high temperatures.

2.1.9 Automatic System Testing

Improper flows of corrosive chemicals or other liquids during a system testrun can cause worker injury or equipment damage.

During a test run of a system, all hand valves must remain closed to prevent

the accidental entry of process fluids.

The water in concentrated chemical piping must be purged completely with

air. Any water remaining in the piping could cause overheating when

chemicals are introduced.

An automatically-controlled system, including the regenerant system, must be test-run

with water prior to the initial operation of the equipment. Operators must be sure that theentire system operates properly (without leaks) before using regenerants or process

liquids.


33/120


34/120



WARNING

WARNING

WARNING

2.2 SPECIFIC SAFETY PRECAUTIONS

This subsection contains the safety precautions for the specific types of equipment that are part

of your U.S. Filter system.

2.2.1 Ion-Exchange Vessels and Storage Tanks

This subsection contains safety precautions specific to storage tanks and to vessels

containing ion exchange resin.

Empty tanks and vessels may tip forward suddenly and without warning,

causing equipment damage or injury to workers.

Always brace tanks and vessels securely until they are loaded or are bolted to

the plant floor.

Tanks and vessels that are empty (contain no liquids or media bed) may not balance whenstood upright. Workers must use extreme caution when working with empty tanks and

vessels and must brace them securely or mount them permanently to the plant floor.

Heavy manhole covers can cause equipment damage or severe personal

injury or death if dropped from any height.

Do not stand under workers who are removing manhole covers. Use extreme

caution when removing or moving heavy manhole covers.

Use extreme caution when removing heavy manhole covers from vessels being loaded. If

lifting davits (arms) are not provided for the covers, use a sling or chain and some type oflifting device to remove and hold the cover. Do not remove all of the cover bolts until it

is certain that the cover is securely slung and supported and will not fall.

Falls from the top of a vessel can cause severe injury or death to workers.

Always load vessels from a platform or lifting device. Platforms and lifting

devices must be equipped with side rails and slip-resistant surfaces where

workers will stand.

Do not stand of top of a vessel while loading it. The curved top surface does

not provide adequate footing, and the lack of hand holds and the smallsurface area can lead to falls.

When a vessel is being loaded, workers must stand on a safe platform or lifting device

and must take all necessary measures to avoid falls.

If a vessel must be loaded using a ladder, use a stable, free-standing ladder that is tall


35/120



WARNING

WARNING

WARNING

enough to allow workers to easily reach the vessel opening. If possible, tie the ladder to

the vessel with a rope.

Confined spaces may contain insufficient oxygen or hazardous chemicals,materials, or vapors, which could result in serious injury or death.

Do not enter a confined space without proper personal protective equipment.

Before and during entry, follow the proper OSHA procedures.

If the vessel must be entered, adhere to the OSHA permit-required confined space

procedures in standard #29 CFR Part 1910.

Process fluids - especially chemicals - entering a vessel while workers are

inside can cause severe injury or death.

Make sure all of the vessel's process entry and exit points have been blinded

off.

Before entering a vessel, verify that all connections to the vessel have been isolated and

tagged out. Also assign a person (called a "spotter") to stay outside the vessel near the

manhole. The spotter should be prepared to give assistance to those inside the vessel or

call for help in the event of an emergency.

Spilled ion exchange resin makes standing and walking extremely hazardousand can lead to falls and worker injury.

If ion exchange resin is spilled on the surfaces where workers must stand and

walk, clean up the media immediately.

When handling vessel media (especially ion-exchange resins), avoid stepping on any of

the media that is spilled. Sweep up and dispose of the spilled media as soon as possible -

refer to the media MSDS in section 2.3 for cleanup details.


36/120



WARNING

2.2.2 Chemical Systems

This subsection covers safety precautions for those systems that use corrosive chemicals,

such as ion exchange systems, chemical day tanks and regenerant dilution stations.

Chemical systems often use highly corrosive chemicals that can cause severe

burns or blindness upon contact.

Wear the proper personal protective equipment (PPE) when handling these

chemicals - refer to the chemical MSDS from the chemical supplier.

Equipment operators must be trained in the safe use and handling of hazardous

chemicals.

Fixed (hard-piped) eye washes and emergency showers should be installed at locationswhere hazardous chemicals are stored or used.

NOTE: Facilities such as eye washes and showers must conform to national and local

safety codes and laws.

In areas where large quantities of hazardous chemicals are stored, emergency ("escape")

respirators should provided.

Workers must wear safety glasses, face shields, respirators, and protective clothing whenworking with corrosive chemicals.

Refer to the material safety data sheets from the chemical suppliers for information on

recommended safety wear, handling procedures, and storage practices for specific

chemicals.

Operators must use extreme caution when working with corrosive chemicals.

Workers must read the chemical safety information in section 2.3 carefully and must be

familiar with basic first-aid procedures for the chemicals used with this system.


37/120



WARNING

WARNING

WARNING

Chemical sprays from pressurized piping can cause severe injury to workers.

Relieve all pressure from piping before performing service.

Wear protective clothing and face protection when disassembling chemicalpiping.

Before servicing components that handle hazardous chemicals, make sure all internal

pressure is relieved and that all chemicals have been drained.

Regenerant chemicals entering a vessel while workers are inside can cause

severe injury or death.

Make sure all of the vessel's process entry and exit points have been closed.

Before entering a vessel connected to chemical systems, follow the guidelines given

earlier in this chapter.

Post warning signs in areas and on components containing hazardous chemicals.

Provide adequate water supply to flood areas of spills - refer to the chemical MSDS's

from the chemical supplier for details on handling chemical spills.

Do not breathe chemical vapors or mists. Protect nose, mouth and lungs from damage by

wearing a NIOSH-approved breathing mask.

If chemicals are mixed manually, add chemicals slowly to the full amount of water and

stir the solution. Never add water to a chemical because boiling and spattering can result.

Do not smoke, weld, or operate electrical equipment that may arc in the vicinity where

hydrochloric acid or volatile chemicals are stored or used.

Corrosive chemical leaks at bolted flanges and other connections can cause

worker injury and equipment damage.

Chemical-resistant safety shields are recommended for all connections in

piping that carries concentrated corrosive chemicals.

The chemical storage, pumping, and mixing systems must be properly piped, valved, and

wired, and must be leak-free. Piping carrying concentrated corrosive chemicals must be

installed properly using the proper chemically-resistant materials, and all flanged

connections should be covered with shields to prevent chemical sprays in the event of

leaks.


38/120


39/120



2.3 MATERIAL SAFETY DATA SHEETS (MSDS's)

This section contains Material Safety Data Sheets (MSDS's) for hazardous chemicals and

materials supplieded with this equipment. These sheets contain important information about

specific hazards and first aid procedures and must be reviewed by all operating personnel.

Refer also to the MSDs for the chemicals used to regenerate the deionizers. These should be

supplied by the chemical supplier.


40/120


PREPARATION AND STARTUP Rev. 0

3.0 PREPARATION AND STARTUP

3.1 EQUIPMENT STORAGE AND INSTALLATION

The purpose of this section is to provide general information on receipt and installation of new

equipment. Procedures for the installation of specific components can be found in the Vendor Literature

Manual.

All equipment must be installed as shown on the piping, wiring and layout drawings for this job. Refer

to the drawings supplied with this equipment when reading and performing the procedures in this

section.

3.1.1 Equipment Handling Procedures

The following guidelines should be observed.

1. All lifting and moving procedures must be performed by experienced construction

workers using standard rigging methods.

2. Before beginning any equipment handling procedures, refer to the following

sections in the Occupational Health and Safety Administration (OSHA) manual

#2206: "General Industry Standards." Also, refer to any other applicable

literature and information for cranes, lift trucks, and other equipment used forlifting and moving.

Subpart N: "Materials Handling and Storage"

Section 1910.176: "Handling Materials - General"

Section 1910.178: "Powered Industrial Trucks"

Section 1910.179: "Overhead and Gantry Cranes:

Section 1919.180: "Locomotive and Truck Cranes"

Section 1919.181: "Slings"


41/120



CAUTION

3.2 INITIAL EQUIPMENT RECEIPT AND INSPECTION

3.2.1 Equipment Inspection upon Receipt

Follow equipment handling guidelines when moving equipment andcomponents and when opening crates.

1. When the job shipment is received, it must be inspected immediately for

completeness and for shipping damage.

NOTE: Unless otherwise specified U.S. Filter equipment is guaranteed against defective

design, materials, and workmanship for eighteen (18) months from the date of

shipment, or for one (1) year from the time of startup. The warranty on individual

component parts not manufactured by U.S. Filter is limited to that of the

manufacturers of those components.

2. Record the item and crate numbers of all received pieces. Some crates will

contain several different tagged items; these crates should be opened temporarily

to check the different items.

Compare the item and crate numbers recorded to those shown on the shipping list

supplied with the equipment, and check off each item that has been located. If

items appear to be missing, contact the carrier and U.S. Filter immediately.

NOTE: Small components that were removed from major components during preparationfor shipping may not have item numbers. These untagged components can be

identified by referring to the piping drawings and the part lists for this job.

3. Perform a close inspection of all major components, piping and sub-components.

Damage can be easily missed during a quick inspection.

Make sure that gauges, sample piping, and tubes have not been damaged or

broken off. Also look for broken, pinched, or bent piping.

4. Perform a close inspection of all shipping crates, boxes and loose components.

Verify that no damage has occurred to these pieces.


42/120


43/120



CAUTION

3.3 STORAGE OF UNASSEMBLED COMPONENTS

3.3.1 General Storage Guidelines

Use the following instructions if the equipment will be stored before it is assembled.

NOTE: To store individual system components (such as instruments, valves, controls etc.) refer

to the manufacturer's storage instructions in the Vendor Literature Manual.

Complete inspection of the equipment.

Place a copy of the marked-up shipping list and the written list of received item numbers

together and store them in a safe place. If necessary, make copies of these lists and distribute

them to the individuals who will be involved in the assembly of the equipment.

Select a storage location where all U.S. Filter equipment can be stored in one area. Avoid

separating equipment, components, and crates.

On large job sites, it is easy for small or separated components to become misplaced or lost.

If the equipment must be separated, note the exact locations of all pieces on the shipping list

or the written list of received pieces.

Set the skids and other components on wooden blocks to keep them out of any standing

water and to protect their painted surfaces.

If possible, store the equipment indoors where it will be protected from sunlight and adverse

weather conditions.

If the equipment will be stored for an extended length of time (inside or outside), cover it

with plastic or canvas tarps to protect it from water, dust, paint over-spray, etc.

If the equipment must be stored outside, special precautions must be taken.

Items that can be damaged by water must be securely wrapped with plastic and covered withtarps.

Storing equipment in direct sunlight may result in the deterioration of

equipment finishes and glued or epoxied parts. The heat from direct

sunlight can weaken or distort plastic and melt the glue used to adhere these

components together.


44/120



CAUTION

Store the equipment in a shaded area or cover it with light-colored tarps.

If outdoor temperatures are warm, remove all vessel manhole covers to allow air circulation.

When the outdoor temperature is below 32F (0C), it is important to verify that the piping,

pumps, valves, and any other components where liquid may have accumulated are

completely drained.

Always drain all liquids from components that must be stored in freezing

temperatures. Expanding ice can damage components.

Open all hand valves on the equipment to allow trapped water and moisture to escape.

To store electrical panels, make sure all of the openings in the panels are sealed with tape andthat the panel doors are securely closed.

When equipment has been stored in extremely hot or cold temperatures and then is moved to

an assembly area, always allow the equipment temperature to stabilize before beginning

assembly. This is especially important if the equipment is very cold.

When equipment is brought out of storage, compare the component quantities with the

original shipping list. Any pieces that are not found at this time must be located quickly to

avoid delays in assembly and startup of the equipment.

Prior to assembly of the equipment, perform a quick recheck for possible equipment damage.


45/120



CAUTION

CAUTION

CAUTION

3.3.2 Storage Instructions For Lined Vessels

Storing equipment in direct sunlight may result in damage to vessel linings.

If lined vessels are stored outside in warm weather, the vessels must beventilated and protected from direct sunlight.

1. If a vessel lining has been damaged, it must be repaired before the vessel is

loaded with resin or other media.

If a vessel is lined with a hard epoxy material, use extreme caution when

moving the vessel when it is cold. Epoxy linings will crack easily when cold.

2. Whenever lined vessels are brought out of storage, the linings must be inspectedfor possible damage.

3.3.3 Storage Instructions For Systems Using Ion-Exchange Resins

Storing equipment in direct sunlight may result in damage to ion exchange

resins.

If loaded vessels are stored outside in warm weather, the vessels must be

ventilated and protected from direct sunlight.

All ion-exchange resins must be stored in temperatures above 35F (2 C). For anion

resins the maximum storage temperature is 95 F (35 C). Cation resins can be stored at

any ambient air temperature above 35F (2 C). Temperatures outside these ranges could

damage the resin.

If vessels are to be stored in temperatures outside acceptable ranges, make sure that the

resin has been removed (refer to the vessel's subsystem operating manual in subsection

5.3). Store resin in a rigid plastic lined container(s) capable of handling the weight of the

resin. Cover resin container(s) and place in a storage area that will be kept within the

specified temperature ranges.


46/120


47/120


48/120



CAUTION

CAUTION

WARNING

8. Connect the required process streams and utilities to the U.S. Filter equipment as indicated on

the piping drawings. Refer to section 1.0 of this manual for the types of process

streams and utilities used with your system.

9. Install any remaining wiring and tubing.

3.4.2 Installation Procedures Specific to Lined Vessels

In extremely cold weather, lined tanks should not be bumped or have

excessive stress applied to them.

Never weld on a lined vessel. High temperatures will damage the vessel

lining.

Some of the vessels for this system may be lined with sheet PVC. Sheet PVC

is a thermoplastic and must not be exposed to temperatures above 150F.

Do not weld on lined vessels. The high temperatures necessary for welding may

damage the lining. If welding must be performed on the vessel legs, do not weld

within 12 inches of the actual vessel.

3.4.3 Chemical System Installation

Highly corrosive chemicals are often used during system operation. Bodily

contact with these chemicals can cause severe burns or blindness. Material

safety data sheets have been provided in section 2.0 for all harmful materials

and chemicals provided with this equipment.

Failure to install, pre-test, and operate the chemical systems properly can

result in serious injury to workers due to leaks and mechanical malfunctions.

Because of the hazardous chemicals used with regenerant and chemical-feed systems,

special attention must be paid to the installation of their components.

1. Position any chemical piping assemblies as indicated on the layout prints.


49/120



CAUTION

2. Always use chemically resistant materials for the chemical system components.

3. All supplied caution and warning labels must be installed and maintained at

chemical storage tanks and other components. If labels are lost or damaged, new

labels are available from U.S. Filter or the component manufacturer.

4. If check valves or chemical ejectors are used, verify that they were installed for

the proper flow direction.

5. When installation is complete, the entire chemical system must be pressure tested

before actual chemicals are introduced.

3.4.4 Pump Installation Procedures

Once single-phase pumps and pump skids have been installed, the alignment

of the pump-drive couplings must be checked and corrected as necessary to

prevent shattering or distortion of the coupling.

1. If pumps are shipped loose (not skid-mounted), they must be positioned and then

mounted and grouted to the floor using approved construction procedures. On

single-phase pumps coupled to motors, align the coupling using the pump

manufacturer's instructions in the Vendor Literature Manual.

NOTE: Do not couple 3-phase pump motors until proper rotational direction has been

achieved (refer to subsection 5.0).

2. Mount the pump motor starters (if applicable) next to the pump or in a common

motor control center. Wire the motor starters to the pump motors and to the main

control panel.

3. Many pump manufacturers ship their pumps without lubricants installed; theselubricants are often shipped in separate containers.

After pumps are mounted and aligned, the proper types and quantities of pump

and gear lubricants should be located and installed.


50/120



CAUTION

CAUTION

3.5 INSTALLATION OF UTILITIES AND OTHER PERIPHERAL EQUIPMENT

This subsection covers utilities and equipment that are required to operate this system but have

not been provided by U.S. Filter.

The equipment and utilities listed here must be connected and operational before the U.S. Filter

equipment can be operated.

3.5.1 Process Feed

The quality of the feed stream must be maintained as described in section 1.0.

3.5.2 Drain Piping (For Waste, Etc.)

Pipe elbows, tees, and other fittings combined with long pipe runs can

increase backpressure to the point that proper drain flows cannot be

achieved.

Drain piping should be as straight and as short as possible. Drain pipes

should be one size larger than the manifold piping.

The drain piping can be piped into headers to drain, but it is best to pipe the individual

component to a sump, drain trench, or other open drain. Open drains make it easier to

take samples and allow for visual observation by the operating personnel.

If the drain flow will contain hazardous or corrosive chemicals, be sure to use piping

materials that will resist these chemicals.

3.5.3 Interconnecting Piping

Liquid pipe-thread sealers and lubricants can contaminate filter elements

and other components. Teflon tape should be used for assembling threaded

piping for high-purity applications.

All customer-supplied piping must be installed at this time. This piping must be flushed

and cleaned before it is connected to the equipment.


51/120


52/120



3.6 SYSTEM PREPARATION CHECKLIST

Piping And Vessels

All equipment installed, leveled, piped anchored, and grounded.

All piping installation completed; inlet, interconnecting and outlet.

Inlet water supply available at required flows and pressure.

All interconnecting piping, air lines, and vessels pressure tested as required, and free of leaks.

Adequate supports and braces provided for all piping

Air Supply

Air supply available at required flows are pressure.

Air lines, including tubing, complete to all enclosures and valves etc.

Air is of instrument quality; free of water or particulate.

Electrical And Instrumentation

Installation of all instruments and devices which were shipped loose.

All electrical tie-ins completed, all circuits rung out; including all 120 VAC, 480 VAC, neutrals,grounds and 4-20 mA current loops to and from field devices.

Instrument calibration checked by qualified technician and documented by log sheet or sticker oneach device.

Pumps And Motors

All pumps utilized by the system grouted in and aligned by a certified millwright.

Motor wiring and MCC complete with proper wire size, fuses, heaters, etc.

Pump motors checked for rotation and vibration prior to coupling.All pumps coupled and lubricated as per manufacturers specifications.

Drain Connections

All drain connections meet unit backpressure requirements.

All drain piping installation complete (at least one pipe size larger than connection at units).

Drain piping tested for leaks where applicable.Note: Drain piping materials must be compatible with chemical waste streams.

Media

Media inventoried and record made of amount and condition.

Media storage to prevent damage by elements, et., direct sun exposure, rain freezing, etc.

Media loaded as indicated by the instructions.

3.7 INSPECTION OF FACTORY-INSTALLED DISTRIBUTION LATERALS


53/120


54/120



Figure 3-1: Lateral Orientation

VP Deionizer Top Distributor

VP Deionizer Bottom Distributor

Gasket

Tank


55/120


56/120



CAUTION

3.8.3 Piping Flush

Do not flush into a vessel; always flush away from a vessel to protect the

vessel distribution piping (if applicable) and keep the vessel clean.

1. Open the various process valves needed to allow water to flow through and flush

the system piping.

To open a solenoid-controlled automatic valve, override its solenoid in the panel

closest to the valve. Refer to the vendor literature for the procedure for the

specific solenoids used.

2. Start the flow of water to the system. If necessary, start a pump to move the flush

water forward.

3. The flush water should now flow through the piping and to drain through the

various effluent outlets.

As the flush continues, close or throttle hand valves as required to direct the water

through all areas of the piping.

While the piping is flushing, open each sample valve in the piping momentarily to

flush all dead legs.

4. When the flush effluent is clear and clean, stop the water flow.

If applicable, turn off the pump, reconnect the valve tubing, and remove the

solenoid overrides.

3.8.4 Vessel Cleaning and Flushing

Inspect the interiors of all pressure vessels.

Remove any large debris or particulates by vacuuming or wiping. Be sure to follow the

Vessel Entry procedures in section 2.0 if entering a vessel to clean it.

Remove smaller particles and dirt by opening any low-point drain valve on the vessel

face-piping, or remove the caps or plugs at the bottom of the piping manifold. Use clean

water to rinse out any remaining dirt.


57/120



WARNING

WARNING

3.9 PRESSURE TESTING

Mechanical failure during pressure testing can result in serious injury to

workers. Do not exceed the pressure rating of components when performing

pressure tests.

Wear eye and face protection when performing pressure tests.

When all equipment and components have been installed, the system must be pressure tested

with water using the following procedures.

3.9.1 General Pressure Test Guidelines

1. Vent the vessel or piping, and fill it with water using the normal inlet valves.

For systems with stainless steel piping or fittings, you may want to use water with

a low chloride content (


58/120



5. When the vessels and piping are completely filled with water, close any vent

valves and allow the pressure to reach the maximum pressure of the inlet pump

(dead-head the pump) or the maximum pressure rating on the system, whichever

is lower. Refer to section 1.0 for vessel pressure ratings.

When the pressure stabilizes, close the inlet valves and turn off the pump to keep

the system at the desired pressure.

6. If possible, allow the system to remain pressurized for several hours, then perform

a close inspection.

7. Tighten any fittings or other bolted components that are leaking. If components

must be disassembled for repairs, be sure to relieve all pressure from the system

first.

NOTE: After the system has been operated at normal temperatures for some time, the

fasteners may require retightening.

3.9.2 Internal Leak Tests for Valves

These tests are intended to insure that the control valves are closing and sealing properly.

1. To check for inward leaks, close all valves and pressurize all inlet and outlet

headers with water. Open all manifold sample valves and allow the manifold to

drain.

If water continues to flow from a sample valve after the manifold is drained, a

leaking valve is indicated.

2. To check for outward leaks, pressurize the vessel and manifold piping with water.

Close all valves and drain any accessible inlet and outlet headers. If water

continues to flow from the inlet and outlet headers after they are drained, aleaking valve is indicated.

3. Valves must be able to hold pressure for a minimum of one hour. Any leaking

valves must be adjusted, repaired, or replaced and then retested before the system

is operated.


59/120



NOTE: If an automatic control valve leaks when closed, check to see if it uses

"bottoming" stops. If these stops are present, adjust the stops according to the

valve manufacturer's instructions.

3.9.3 External Leak Tests for Vessels with Windows

This subsection describes the procedures for pressure-testing vessels with windows, to

check for external (visible) leaks.

1. Make sure that all of the nuts are too tight to spin by hand. If not, loosen all of

the nuts to hand-tight, and tighten them to 12 ft-lbs in 2 ft-lb increments. Tighten

them in the order shown on the next page.

2. If a leak occurs at a vessel window, tighten the window nuts in 2 ft-lb incrementsuntil the leak stops or until the maximum torque is reached, as shown in the table

below. Tighten in the sequence shown on the drawings that follow the table.

After repairs are made, pressurize the system again to double-check these repairs.

Table 3-1: Window Tightening Pressures/Torques

Maximum Pressure (psig) Maximum Bolt Torque (ft-lbs)

75 12

100 14

150 18

200 22


60/120



Figure 3-2: Tightening Rectangular Windows Figure 3-3: Tightening Round Windows


61/120



3.10 VESSEL LOADING

2.10.1 General Guidelines for Loading Ion-Exchange Vessels

The following are guidelines for loading two-beds and mixed-bed exchangers.

1. Remove the manhole cover on the top or upper sidesheet of the vessel (refer to

section 2.0 for safety precautions). On small vessels with no manhole, disconnect

the piping going into the top of the vessel, remove the bolts holding the flanged

top piece to the spool body of the vessel, and lift off the entire top piece.

2. Prior to loading any media into a vessel, all internal distribution must be inspected

using the procedures given earlier in this section, and the vessel must be cleaned

to remove foreign material.

If the distribution laterals are wrapped with steel or plastic screen, check the

wrappings carefully for tears or breaks. Use extreme care when working with

wrapped laterals.

3. The vessel to be loaded must be properly leveled and braced before loading

begins.

4. Refer to Section 1.0 of the main manual for the sizes, types, and quantities of

media to be loaded into each vessel or tank.

To find the relationship between media weight and volume, use the table in

Section 1.2.10 of the main manual.

While loading each two-bed, be sure to fill out the data form at the end of this

Section of the main manual.


62/120


63/120



3.10.4 Loading Ion-Exchange Vessels (except Mixed-Beds)

The following are general guidelines for loading resin in an ion-exchange or chelationvessel, with the exception of mixed-bed deionizers. Examples of these vessels are

softeners, dealkalizers, and the cation and anion vessels in a two-bed deionizer.

NOTE: When loading anion resin, use soft or deionized water to fill the vessel.

1. Before loading any resins, always verify that the proper resins are being used.

Cation and anion resins must not be mixed or placed in the wrong vessels.

Prior to loading resins into process vessels, record the lot or batch number(s) of

the resin. When loading the resins, record the installed location (vessel number orname) of each lot or batch of resin.

If resin container labels are missing or if there is doubt about the identity of a

resin, contact U.S. Filter or the resin manufacturer.

4. Larger quantities of resin are most conveniently loaded using a large eductor.

The eductor draw line is inserted directly into a shipping drum and the eductor

outlet line is placed in the vessel manhole or is connected to a resin sluice nozzle

near the top of the vessel (where applicable). Once the eductor motive flow is

started, a separate sluice (fluidization) line must be inserted into the drum to keepthe resin fluidized.

When transferring resin with an eductor, some of the water in the vessel may have

to be drained out as the transfer progresses.

5. If the resin is new, it must receive an initial regeneration before being placed in

Service. Perform all startup procedures given later in this section.


64/120


65/120



4. Calibrate all of the instrumentation on the system using the manufacturers'

instructions in the Vendor Literature Manual.

5. Verify that the vessels have been properly loaded using the instructions givenearlier in this chapter.

6. Regenerate the two-bed unit using normal start-up procedures with the following

exceptions:

A. Extend the backwash steps so that each step lasts until the backwash

effluent is clear and clean.

B. Extend all of the chemical-in steps so that each step lasts twice as long as

indicated in the Regeneration Sequence in section 1.2.13. New resins

require twice the normal amount of chemicals for the first regeneration.

8. Following the initial regeneration of the unit, put the system into Service. This

completes the startup of the two-bed system.


66/120


67/120



SERVICE DATA

12. Record the minutes used during the leak test.

13. Record the pressure during the leak test.

14. Record the feed temperature during service.

15. Are the chemical tanks full, empty, clean, etc?

16. Record the flow rate during service.

17. Record the test method used to determine the flow rate.

eg. Flow indicator FI-1

18. Record the feed pressure during service.

eg. Pressure indicator PI-1

19. Record the test method used to determine the pressure.

20. Record the ph during service. This should be taken as soon after a regeneration as

possible.

21. Record the test method used to determine the ph.

eg. paper, handheld meter, meter ph-1

PERFORMANCE DATA

22. Record the conductivity during service

23. Record the test method used to determine conductivity

eg. Thornton L, CE-1

REFERENCE DATA

24 Record the resin loaded into the vessel, use the marking on the drum or bag

eg. C-211, A-264 P/N XYZ

25. Record the lot number of the resin, use the markings on the bag or drum.

26. Record the cubic feet of resin loaded.

27. This area is used for systems that require subfill. This system does not use subfill

underneath the resin.

28. Quantity in pounds or cubic feed of each layer of subfill.

29. Record the type and grade of chemicals used for regeneration.

eg. HCl-Technical, NaOH Rayon

30. Record the concentrated chemical concentration.

eg. 20%, 50%

31. Record the dilute chemical concentration (to the bed).

eg. 4%


68/120



32. Record the gallons of concentrated chemical used per regeneration.

eg. 50 gallons

33. Indicated that these items have been checked.

34. Record the voltage the main panel is operating at.

eg. 120V

35. Any comment the US Filter service person deems to be reportable.

GENERAL

36. Name of US Filter service person who performed the work. Must

include printed last name.

37. Date the actual work was completed.


69/120




70/120


OPERATION Rev. 0

WARNING

4.0 OPERATION

This section gives the procedures needed to operate the VP Series two-bed deionizer system for units

that consist of a cation exchanger, an anion exchanger, a customer-supplied acid day tank, and a

customer-supplied c