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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]
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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
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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
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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.
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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
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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.
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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.
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VP TWO-BED DEIONIZER Page 1-3
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
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VP TWO-BED DEIONIZER Page 1-4
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
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VP TWO-BED DEIONIZER Page 1-5
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
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VP TWO-BED DEIONIZER Page 1-6
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.
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VP TWO-BED DEIONIZER Page 1-7
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.
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VP TWO-BED DEIONIZER Page 1-8
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.
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VP TWO-BED DEIONIZER Page 1-9
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.
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VP TWO-BED DEIONIZER Page 1-10
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.
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VP TWO-BED DEIONIZER Page 1-11
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.
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VP TWO-BED DEIONIZER Page 1-12
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.
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VP TWO-BED DEIONIZER Page 1-13
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.
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VP TWO-BED DEIONIZER Page 1-14
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.
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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
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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.
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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.
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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.
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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.
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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.
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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.
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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.
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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
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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.
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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.
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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.
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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.
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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"
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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.
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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.
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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.
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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.
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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.
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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.
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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.
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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
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Figure 3-1: Lateral Orientation
VP Deionizer Top Distributor
VP Deionizer Bottom Distributor
Gasket
Tank
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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.
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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 (
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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.
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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
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Figure 3-2: Tightening Rectangular Windows Figure 3-3: Tightening Round Windows
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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.
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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.
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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.
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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%
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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.
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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