E-Cell Mk-2E User Manual - Industry Surplus Australia
Contents
1. ensure rectifier power is off and the rectifier properly tagged and or locked out 11 2 3 Cleaning Chemical Specifications All chemicals must be of recommended grade or better Sodium Chloride NaCl Food Grade 299 8096 ACS or USP grade Halane 1 3 Dichloro 5 5 dimethyl hydantoin USP or ACS grade Peracetic Acid CH3COOOH and Hydrogen Peroxide H202 30 ACS grade or commercial concentrate for water system cleaning ex Minntec Minncare Henkel Ecolab Oxonia Active Diversey Divosan or FMC Flocide Hydrochloric Acid HCI ACS or Technical grade Sodium Hydroxide NaOH Pellets NF ACS or Purified grade or 50 w w Solution 11 5 CLEANING SETUP AND INSTRUCTIONS There are eight cleaning procedures in total made up of combinations of four basic types of cleaning low pH high pH mild oxidizing sanitization cleaning and sodium chloride rinse The first cleaning procedure is performed only on the Concentrate and Electrode chambers of the Stack Its setup is different from the remaining seven procedures where cleaning is done on all chambers Dilute Concentrate and Electrode The description of the four cleaning types is laid out in this section as are the descriptions of the water rinse and final water rinse The list of individual steps is shown for procedures 2 through 8 Procedure 1 is laid out in detail in its own section A cleaning tank and pump and four hoses to connect the tank and pump to the E Cell System are requ2. 100 F 4 4 to 38 C Inlet Pressure 50 to 100 psig 3 4 to 6 9 bar Minimum to Nominal flow 65 to 100 psig 4 5 to 6 9 bar Maximum flow Feed to Product AP 20 to 35 psid 1 4 to 2 4 bar Nominal flow 10 to 15 psid 0 7 to 1 0 bar Minimum flow 40 to 50 psid 2 8 to 3 4 bar Maximum flow Recovery 90 to 95 Electrical Power Up to 600 VDC MK 2E MK 2Pharm MK 2PharmHT Stack Up to 300 VDC MK 2Mini MK2 MiniHT 0 5 to 4 5 amp See section Concentrate Bleed Stream for information on recovery and feedwater hardness rev 1 1 Page 3 6 3 5 E CELL STACK TECHNICAL DATA SHEET Design Pressure Of E Cell Stack eet terrm ieget 100 psig 6 8 Bar Membrane Manufacturers EE Asahi Glass Corporation AGC lon Exchange Geier ele Mitsubishi Chemical Model Designations MK 2E MK 2Pharm MK 2PharmHT MK 2Mini MK 2MiniHT Anode Mata io IrOx TiO2 on Ti Cathode Mat A A a Stainless Steel EE E See Cutsheet 3 6 PERFORMANCE DATA Maximum System Product Flow Rate EE See Cutsheet Minimum system Product Flow ROle ast eet nao See Cutsheet MK 2E MK2 Pharm MK 2PharmHT Stack Product Flow Rate ss SE Minimum 7 5 gpm 1 70 m3 hr re eT ETE Nominal 15 0 gpm 3 41 m3 hr M EE EN Maximum 20 0 gpm 4 54 m3 hr MK 2Mini MK 2MiniHT Stack Product Flow Rote M I Minumum 2 5 gpm 0 57 m3 hr eebe Nominal 5 0 gpm 1 14 m3 hr MONDIAL CANC LAC T AM D D M ME TEA Maximum 6 7 gpm 1 52 m3
3. Cl gas will dissolve into the solution The presence of oxidants combined with the venting requirements and the small flow rate lead to this stream flowing to drain in most installations rather than being recovered The Electrode stream is supplied from the Concentrate stream 10 2 OPERATING PRESSURES The Concentrate stream must always operate at a lower pressure than the Dilute stream to maintain high product water quality The Concentrate inlet must be at least 5 psi 0 3 bar less than the Dilute inlet pressure The Concentrate outlet must be at least 5 psi 0 5 bar less than the Dilute outlet pressure The Concentrate Inlet valve controls the inlet pressure difference Closing the valve decreases the Concentrate Inlet pressure and thereby increases the pressure difference rev 1 1 Page 10 19 between the Concentrate Inlet and Dilute Inlet The Concentrate By pass valve controls the outlet pressure difference Closing the valve decreases the Concentrate outlet pressure and thereby increases the pressure difference between the Concentrate outlet and Dilute outlet The maximum E Cell Dilute Feed water pressure is 100 psi 6 8 bar PRESSURE DIFFERENCE BETWEEN DILUTE AND CONCENTRATE rev 1 1 Page 10 20 10 5 OPERATING DATA The E Cell System requires little maintenance however it is important to keep accurate operating data This should be used to track the performance of the
4. Where hardness or other metallic scale is present along with heavy biological fouling an acid Cleaning step is added to the beginning of the procedure Halane a widely used source of chlorine is useful for cleaning and sanitizing high purity water treatment equipment Peracetic acid 0 0496 hydrogen peroxide 0 296 performs similarly using a different chemical species Due to their oxidizing power these cleaning solutions should be used infrequently For severe biological fouling a high pH step is added to the procedure for improved efficiency teps Cleaning Setup Instruction 1 Instruction 5 Instruction 6 Instruction 3 or Instruction 4 NOT BOTH Instruction 2 Instruction 7 rev 1 1 Page 11 29
5. coe oleae ii lect 5 9 MECHANICAL AND HYDRAULIC cccccccsscsccscssccccccccccccccssccccccccccccccsccccsccccscecccsccccscs 6 9 RECEIVING INSTALLATION 2 cccccscccccccccscsccssccccccccccccccscccccceccccecccsccscccsccccscececes 7 10 7 1 RECEIVING ebe 7 10 7 2 ESSEN E oom coectetuer a PELLE fe Et m T 7 10 7 3 E SCEPLESTACKIMSTO RAGE Rud a GIN 7 10 7 4 INSTALLATION zu 3 recto ote ecce EE 7 10 7 5 DRAINS VENTING wii ceesceseccccccccccensseseecececcccsneseeescccececcanssseececececcanenseeeseeeeceaaes 7 11 8 START UP ee L er 8 12 8 1 GENERAL OVERVIEW oso cm oboe ice ceeded ons Sear ovale th drat cree Med Pace tare MI 8 12 8 2 STARTS ufo eec E ovest trei acacia 8 12 8 2 1 Fill the system with water and establish Dilute How 8 13 8 2 2 Establish Concentrate Electrode and Dilute Flow 8 14 8 2 3 Confirm all flows and pressure ria 8 15 eo oltre DE ele UE 8 15 9 SHUT DOWN PROCEDURES eigene sses sgeieseie etete de eg ca se n e a aao Eege 9 16 9 1 E CELL STACK SHUT DOWN FROM AUTOMATIC OPERATION eere 9 16 9 2 E CELL STACK PROLONGED SHUT DOWN emen eene nennen esee neu 9 16 10 OPERATING INSTRUCTIONS 5 ee eo eer o eie no o eau nn o eo no e o ea eee No po Pro eie eo se rao e e Pena 10 17 10d Re E TEE 10 17 ek E BR el de e e S ctc c II EE 10 17 1031 2 Concentrate STO Mii tt et
6. hr REENEN 90 9596 MK 2E MK 2Pharm MK 2PharmHT Stack voltage input 100 V 600 V MK 2Mini MK 2MiniHT Stack voltage input ENEE 100 V 300 V SIC ie ue EE 0 5A 4 5A rev 1 1 Page 3 7 3 7 E CELL CE CSA and NRTL C COMPLIANCE The E Cell Stack meets the principle elements of the safety objectives for the low voltage directive EC Directive 73 23 EEC having applied the following standard BS EN 60204 1 The E Cell Stack meets the principal elements of the safety objectives for the electro magnetic compatibility directive EC Directive 89 336 EEC as amended by 92 31 EEC and 93 68 EEC The following standards have also been applied EN 55011 1995 Group 1 Class A EN 610001 4 2 EN 610001 4 3 EN 610001 4 4 EN 610001 4 5 EN 610001 4 6 EN 610001 4 11 In addition the E Cell Stack has CSA and NRTL C certification 4 BRINE INJECTION E Cell Stacks with low feed water conductivity may not be able to maintain sufficient current flow Stacks Without sufficient current flow the E Cell Stacks will be unable to produce high quality water In case of low conductivity feed the concentrate water can be supplemented with brine to attain high quality product water Brine injection is also required where feed water contains greater than 0 1 ppm as CaCO of hardness 5 ELECTRICAL The E Cell Stack uses high voltage DC power Standard good electrical practices apply and they a
7. 0 91 gpm 0 21 m3 hr Concentrate Bleed flow for each MK 2Mini or MK 2MiniHT Stack The electrode stream must be vented as it contains small quantities of hydrogen oxygen and possibly chlorine gas A 2 1 mixture of hydrogen and oxygen gas is produced at a maximum rate of about 11 4 ml amp minute hydrogen dry gas at 25 C 1 0 atm Ensure ventilation maintains the hydrogen gas levels below 496 Drains should be designed so that the E Cell Stack cannot drain while in Standby rev 1 1 Page 7 11 8 START UP 8 1 GENERAL OVERVIEW The basic steps involved in the system start up are Fill the system with Reverse Osmosis quality water or better Set dilute flow Start the concentrate pump and establish concentrate flow Set concentrate bleed flow Set the concentrate inlet pressure Set the concentrate outlet pressure Set the electrode flow Start the rectifier CONAN PNNE 8 2 START UP Once the E Cell Stacks are ready for start up the Concentrate Loop must be filled The initial filling is done with R O permeate or other high quality water The feed water must always meet all the quality requirements this will require the R O to be rinsed to quality before being placed into Service and sending water to the E Cell System The conductivity of the Concentrate loop will initially be the same as the Feed water conductivity In order for the E Cell Stacks to function effectively the Concentrate Loop should have an operat
8. AKE UP CONCENTRATE LOOP CONCENTRATE RECYCLE DILUTE FEED E CALC ELECTRODE STREAM GEWPT PRODUCT RECTIFIER rev 1 1 A small portion of the Concentrate flow which is sent to drain The Concentrate make up is the additional water added to the Concentrate loop to make up the volume sent to drain via the Electrode outlet and the Concentrate bleed The Concentrate loop is from the Concentrate Pump to the E Cell Stack and back to the pump A portion of the Concentrate flow is recycled through the Stacks in order to maintain the required conductivity in the Concentrate loop Flow through the E Cell Stacks that will become Product water An E Calc spreadsheet available from GEWPT calculates all E Cell EDI process parameters based on feed water analysis and selected operating conditions A small portion of recycled Concentrate flowing through the Electrode compartment of each E Cell Stack of the E Cell System which will be sent directly to drain after exiting the System GE Water and Process Technology The deionized water which is produced by the E Cell System DC power supply Page 1 2 2 PERSONNEL SAFETY PRECAUTIONS The following Pictograms can be found on the E Cell Stack and contained in this Manual Pictogram Function Description WARNING The E Cell Stack should not be used at any time by untrained personnel Do not attempt to operate the E Cell Stack u
9. GE WATER amp PROCESS TECHNOLOGIES E CELL STACK MK 2 SERIES OWNER S MANUAL 2006 General Electric All rights reserved No part of this publication may be reproduced stored in a retrievable system or transmitted in any form or by any means electronic mechanical photocopying recording or otherwise without the prior written permission of GE For additional E Cell Stack information go to the GEWPT E Cell web page http www ecell com rev 1 1 Page 1 1 TABLE OF CONTENTS E CELESTACKM GLOSSARY 45 estote serv esce eroe tea Te Eege soe feste Teo Ve do ee e ea UN Eque 1 2 2 PERSONNEL SAFETY PRECAUTIONS eeeee eene eere eene eene a no nette eese e ssas eese e eese tasses EEN 2 3 HG elle up el KEEN 3 5 3 1 FEED WATER SPEGIFICATIONS Ee ee oie td ree eee na ee eoe nece Seet 3 5 3 2 PRODUCT WATER SPECIFICATIONS ccccccccccccceseseececccccecceseseecsccceccecuaesseeecececeecunensess 3 6 3 3 SAEESPECIFIGATIONS secures a Hee dE le Ee 3 6 3 4 E CELL STACK OPERATING DARAMETIERG nennen eese ense erre 3 6 3 5 E CELL STACK TECHNICAL D AIAGHEET enne nennen enne nenn nnne 3 7 3 6 PERFORMANCE DATA ences neh anton e ees a e ceil pd de 3 7 3 7 E CELL CE CSA and NRTL C COMDUANCE emen eene 3 8 Ay BRINE INJECTION eege rere egener nS se eee beten Eege 4 8 ELECT RICA Ye Pm ta aaas eaae i 5 8 5 1 E CELL STACK MAXIMUM POWER REQUIREMENTS eee 5 9 5 2 OPERATING CURRENT ee Ee eee ete Ee
10. ally without the flow of water through any channels they will be irreversibly damaged in 1 3 minutes Systems with an open system between the RO and E Cell ex tank decarbonator must be fitted with filters immediately preceding the E Cell to protect the E Cell against contamination with particulate matter Generally a 5um absolute or 1um nominal filter will be acceptable For your specific system requirements consult your E Cell System Integrator Common causes of blockage e PVC shavings cement or other debris from pipe work flushed into stack inlets e Slime or debris from a tank not filtered before going into E Cell e Improper set points on flow switches or transmitters or malfunctioning disabled flow meters e Accidental closing of manual valves BEFORE APPLYING ELECTRICITY OR WATER TO THE E CELL e Flush piping thoroughly with filtered water to drain before connecting feed water piping to the E Cell Stacks Failure to flush the pipes to remove debris may cause irreversible damage to the stacks e Pressurize stacks slowly over 1 2 minutes to avoid severe damage from water hammer Do not over pressurize stacks e Ensure 4 flows have been established and all safety interlocks have been proven Electrode Outlet flow Dilute Product Outlet flow Concentrate Inlet flow and Concentrate Bleed flow e Verify that no chlorine or oxidizing agent enters the E Cell Stockem Water must meet feed specifications e Operation at g
11. d Cleaning of All Chambers Chloride Sodium Hydroxide Cleaning Sanitizing This procedure provides an acid cleaning of Sodium chloride 5 sodium hydroxide 1 all chambers of the Stacks to clean hardness is useful for cleaning fouling due to organics and other metallic scale or to biological growth and for sanitization It can also clean light silica scaling Steps Steps Cleaning Setup Instruction instruction2 struct nstructionZ rev 1 1 Page 11 27 Cleaning Procedure 4 Hydrochloric Acid and Sodium Chloride Sodium Hydroxide Cleaning Sanitizing This procedure provides an acid cleaning of all chambers of the Stacks to remove inorganic metallic scale Sodium chloride 596 sodium hydroxide 196 is useful for cleaning fouling due to organics or to biological growth and for sanitization It can Cleaning Procedure 5 Halane or Peracetic Acid Sanitizing Halane a widely used source of chlorine is useful for cleaning and sanitizing high purity water treatment equipment Peracetic acid 0 0496 hydrogen peroxide 0 296 performs similarly using a different chemical species Due to their oxidizing power these cleaning solutions should be used infrequently also clean light silica scaling Steps instructionS Instruction6 o oS Instruction 3 or Instruction 4 NOT BOTH Instructions instruction Cleaning Setup Instruction 1 Instruction 6 Instruction 2 Instruc
12. e Instruction 7 Final Water Rinse e Drain the cleaning skid and E Cell skid e Fill the cleaning tank with 25 L per Stack of RO or better quality water e Briefly recirculate the water and then drain the cleaning skid and E Cell skid e Repeat the rinse steps until the Concentrate Outlet conductivity is lt 50 uS cm rev 1 1 Page 11 26 11 4 CLEANING PROCEDURES Cleaning Procedure 1 Hydrochloric Acid Cleaning of Concentrate and Electrode Chambers This procedure provides an acid cleaning of the Concentrate and Electrode anode and Steps Cleaning Setup Concentrate and Electrode Acid Cleaning Procedure Only Isolate the Concentrate and Electrode loops from the Dilute loop by closing the Concentrate Makeup valve Isolate the Concentrate pump by closing the Concentrate pump suction and discharge valves Close the Concentrate Bypass valve Close the Concentrate Bleed valve Connect the cleaning skid discharge to the E Cell Concentrate Inlet cleaning connection Connect the E Cell Concentrate Outlet and Electrode Outlet cleaning connections back to the cleaning skid Hydrochloric Acid Solution Recirculation Concentrate and Electrode Acid Cleaning Procedure Only e Make up 50 L per Stack of HCI 1 8 solution e Recirculate the HCI solution through the Concentrate and Electrode loops for 30 minutes with flow ranges as during normal operation Final Water Rinse Cleaning Procedure 2 Hydrochloric Cleaning Procedure 3 Sodium Aci
13. e In conditions with very low Feed water pressures it may be necessary to throttle the Concentrate Pump Discharge Valve in order to achieve the required flows and pressures This is the reason for the diaphragm valve on the pump discharge rev 1 1 Page 8 14 EN 8 2 3 Confirm all flows and pressures Electrode flow is 0 35 gom Stack 80 l h Dilute Flow is 7 5 20 0 gpm 1 70 4 54 m3 h per MK 2E MK 2Pharm or MK 2PharmHT Stack 2 5 6 7 gpm 0 57 1 52 m3 h per MK 2Mini or MK 2MiniHT Stack Concentrate Bleed Flow is set for the appropriate recovery Dilute Feed pressure is at least 5 psi 0 35 bar more than Concentrate Inlet pressure Dilute Product pressure is at least 5 psi 0 35 bar more than Concentrate Outlet pressure 8 2 4 Initiate DC power Set current to 096 Set voltage to 10096 maximum of 600 Volts for MK 2E MK 2Pharm or MK 2PharmHT Stacks maximum 300 Volts for MK 2Mini or MK 2MiniHT Stacks Slowly increase current to 2 amps E Cell Stack If the concentrate conductivity is low the maximum current will also be low As the concentrate conductivity increases so will the current Note The Brine Pump is set in the Off position because the conductivity in the Concentrate loop may be high enough to allow sufficient current flow If the Concentrate loop conductivity remains below 50 uS cm after half an hour of operation start the Brine Pump by selecting AUTO Below 50 uS cm current flow may be too low Th
14. e brine injection should be ramped up very slowly to prevent a sudden conductivity increase and therefore a sudden current increase through the E Cell Stacks which could blow a fuse E Cell Stacks are shipped in regenerated form but they could be exhausted to certain degree during startup activities when water is passed through them without current Therefore it may take some time until the stacks are fully regenerated and produce water of required quality typically it takes few minutes rev 1 1 Page 8 15 9 SHUT DOWN PROCEDURES 9 1 E CELL STACK SHUT DOWN FROM AUTOMATIC OPERATION If the system is to be shut down for a period of time and the piping configuration allows the system to drain some of the manual valves must be closed They include the following Close the Dilute Feed Inlet Valve Close the Dilute Product Outlet Valve Close the Dilute Product Rinse Valve Close the Concentrate Bleed Valve Close the Electrode Outlet Valve UY d eA ES 9 2 E CELL STACK PROLONGED SHUT DOWN If the E Cell Stacks are to be shut down for more than three days they must be prepared for long term shutdown and storage to hinder the development of biogrowth Note Power to the E Cell Stacks must be off during all steps of the preparation for long term shutdown Notes 1 Power to the E Cell Stacks must be off 2 Allow E Cell Stacks to drain all standing water 3 Close or cap all E Cell Stacks inlet and outlets so
15. erne erect dooce 10 17 10 1 3 Concentrate Bleed Stream ET 10 18 TAE Electrode dee EE 10 19 10 2 OPERATING PRESSURES r ran n n a a a da e e a Aa a 10 19 10 57 OPERATING DATA 29r a te a N NO 10 21 rev 1 1 Page 1 2 11 PREVENTATIVE MAINTENANCE cis coscsinsseatspcicctesseasesadsensenesvudenstssctastadsecesseosacceaustenease 11 22 e OCTET IE EE 11 22 11 2 E CELL STACK CLEANING AND SANIT IZING aii 11 22 A AAA A O A 11 22 DA Bek E 11 24 11 2 3 Eeer 11 24 11 3 CLEANING SETUP AND e a ent e EE 11 24 TLG LEANING PROCEDURES erger err tes abes Edge A 11 27 Cleaning Procedure 1 Hydrochloric Acid Cleaning of Concentrate and Electrode Chambers 11 27 Cleaning Procedure 2 Hydrochloric Acid Cleaning of All Chambers 11 27 Cleaning Procedure 3 Sodium Chloride Sodium Hydroxide Cleaning Sanitizing 11 27 Cleaning Procedure 4 Hydrochloric Acid and Sodium Chloride Sodium Hydroxide E e Tigre e e EE 11 28 Cleaning Procedure 5 Halane or Peracetic Acid Sanitizing sss 11 28 Cleaning Procedure 6 Hydrochloric Acid and Halane or Peracetic Acid Sanitizing 11 28 Cleaning Procedure 7 Halane or Peracetic Acid Sanitizing and High pH Sanitizing 11 28 Cleaning Procedure 8 Hydrochloric Acid and Halane or Peracetic Acid Sanitizing and High le sien A A p TR 11 29 rev 1 1 Page 1 3 1 E CELLSTACK GLOSSARY CONCENTRATE BLEED CONCENTRATE M
16. for actual weight The E Cell Stack cannot be lifted or moved or supported by the SaniTech hose connections 7 5 E CELL STACK STORAGE The E Cell Stack should be stored indoors out of direct sunlight and at a temperature between 33 F 2 C and 120 F 49 C The membranes inside the E Cell Stack must be maintained wet The Stack must remain full of water if stored for up to three days For longer storage of up to one year the E Cell Stack must be drained of water and capped to keep the Stack moist Whenever a Stack is stored it should be on its back with the nozzles pointing up 7 4 INSTALLATION The E Cell Stacks are Installation Category II as well as Pollution Degree 2 Remove all dust caps from the E Cell Stack and connect the hoses Hand tighten the SaniTech fittings The E Cell Stack installation must be protected from wind rain direct sunlight vibration and meet the following operating environment for the E Cell Stack Parameter Range Temperature range 33 F 2 C to 120 F 49 C Humidity up to 95 Seismic Zone 1 Altitude 0 to 6 560 ft 2 000 m rev 1 1 Page 7 10 7 5 DRAINS VENTING Drains should be designed to carry away 20 gpm 4 54 m3 hr Product flow 0 40 gpm 90 L hr Electrode Outlet flow and 1 97 gpm 0 45 m3 hr Concentrate Bleed flow for each MK 2E MK 2Pharm or MK 2PharmHT Stack and 6 7 gpm 1 52 m3 h Product flow 0 40 gpm 90 L hr Electrode Outlet flow and
17. g high pressure water Check for proper recovery ratio once per week minimum Check feed water quality on a regular basis 11 2 E CELL STACK CLEANING AND SANITIZING 112 1 Overview Over time cleaning and or sanitization of E Cell Stacks may be necessary due to hardness or other metallic scaling mainly in the Concentrate and Cathode chambers fouling of the ion exchange medium or membranes with inorganic material ex silica fouling of the ion exchange medium or membranes with organic material M biological fouling of the E Cell Stack and system piping and components combinations of the above In some cases more than one type of cleaning may be needed The chart below summarizes the scaling and fouling conditions and the cleaning sanitizing procedures best suited to correct the condition The MK 2PharmHT and MK 2Mini HT Stacks can be sanitized at high temperature 809 C 1769F For instructions refer to the separate MK 2 Pharm HT Mini HT Sanitization Procedure rev 1 1 Page 11 22 Cleaning Procedure 1 2 3 4 5 6 7 8 PROBLEM Jo p gu messe j j metallic scaling Seance LL metallic scaling Organic fouling Yes Organic fouling and BE A A TE A Yes Des Biological fouling veel J J and metallic scaling fouling Heavy biological Yes fouling and metallic scaling a MN UU ES SSES KA fouling Severe biological Yes fou
18. he Concentrate stream should be kept between 50 and 600 uS cm This will allow sufficient current flow through the E Cell Stack For applications with very low conductivity feed water brine can be injected directly into the Concentrate loop to raise the conductivity Note The Recovery must never be increased in order to increase the conductivity in the Concentrate loop The Concentrate Bleed flow must be set to achieve the required recovery rate If the Concentrate Bleed flow is decreased the maximum allowable recovery will be exceeded and scaling of the Concentrate chamber will begin 10 1 3 Concentrate Bleed Stream Range Dependent on required recovery ratio lons removed from the Dilute stream must be expelled from the E Cell Stack through the Concentrate Bleed stream to prevent scaling The Concentrate Bleed flow required is dependent on the amount of hardness Recovery ratios have been calculated to maintain an acceptable hardness level Feed Hardness E Cell NaCl Injection into C loop 2 ppm as Caco Recovery uS cm 0 0 0 10 9596 0 10 0 50 9096 400 500 WU Lowering the recovery lowers the hardness level in the concentrate loop and hence decreases the scaling potential 2 NaCl injection also reduces the electrical resistance of the stack and hence the power consumption At feed hardness levels 0 1 ppm a maximum recovery of 9596 applies and periodic cleanings are generally not required in
19. ing conductivity of 50 600 uS cm In some cases it may be necessary to inject concentrated brine into the Concentrate Loop in order to raise the conductivity once the system is operating E Calc spreadsheet indicates if brine injection is necessary and calculates expected concentrate conductivity based on feed water analysis and recovery rev 1 1 Page 8 12 P but NAW E but eo E CELL SYSTEM SCHEMATIC E CELL DILUTE FEED INLET STACK DILUTE PRODUCT OUTLET C px CONCENTRATE MAKE UP X T CONCENTRATE DILUTE INLET RINSE BRINE Lu OUTLET INJECTION ELECTRODE OUTLET PUMP CONCENTRATE DISCHARGE BLEED SUCTION CONCENTRATE PUMP LEGEND BIR VALVE Q PRESSURE INDICATOR T DRAIN JL CLEANING CONNECTION X CHECK VALVE FLOW DIRECTION C FLOW INDICATOR Before E Cell Stacks start check All Valves are closed All pumps are in the OFF position DC power is turned OFF Safety equipment is installed and operational 8 2 1 Fill the system with water and establish Dilute Flow Open Concentrate Make up Valve Open Concentrate Inlet Valve Open Pump Suction Valve Open Pump Discharge Valve Open the Concentrate Bleed Valve Open the Dilute Rinse Outlet Valve Slowly crack open the Dilute Feed Inlet Valve maintain a low feed pressure less than 40 psi to the E Cell Stacks to ensure a slow Concentrate Loop and Dilute Loop fill Adjust the Dilute Rinse Outlet Valve to establish the correct flo
20. ired for procedures 2 through 8 for procedure 1 only three hoses are required rev 1 1 Page 11 24 Cleaning Setup e Isolate the E Cell system from upstream and downstream by closing the E Cell System Dilute Feed Inlet Dilute Product Outlet and Dilute Rinse Outlet valves e Connect the cleaning skid discharge to the E Cell Dilute Feed Inlet cleaning connection e Connect the E Cell Dilute Product Outlet Concentrate Bleed and Electrode Outlet cleaning connections back to the cleaning skid Instruction 1 Hydrochloric Acid Solution Recirculation Low pH Cleaning e Drain the cleaning skid and E Cell skid e Make up 50 L per Stack of HCI 1 8 solution e Recirculate the HCI solution through the Dilute Concentrate and Electrode loops for 30 minutes o The E Cell system will run with flow ranges as during normal operation using the Concentrate pump but with no current applied to the Stacks Use To clean hardness and other metallic scale In procedure 1 only the Concentrate and Electrode chambers of the stack are cleaned Instruction 2 Sodium Chloride Sodium Hydroxide Solution Recirculation High pH Cleaning e Drain the cleaning skid and E Cell skid e Make up 25 L per Stack of NaCl 5 NaOH 1 solution e Recirculate the NaCl NaOH solution through the Dilute Concentrate and Electrode loops for 30 minutes o The E Cell system will run with flow ranges as during normal operation using the Concentrate pump but with no current app
21. lied to the Stacks Use Sodium chloride with sodium hydroxide is useful for cleaning fouling due to organics or to biological growth and for sanitization It can also clean light silica scaling Instruction 3 Halane 1 3 dichloro 5 5 dimethyl hydantoin Solution Recirculation Mild Oxidizing Sanitization Cleaning e Drain the cleaning skid and E Cell skid e Make up 25 L per Stack of halane 0 05 solution 12 5 g halane in 25 L of water o Halane is sparingly soluble Completely dissolve the halane before proceeding to recirculate the cleaning solution e Recirculate the halane solution through the Dilute Concentrate and Electrode loops for 30 minutes o The E Cell system will run with flow ranges as during normal operation using the Concentrate pump but with no current applied to the Stacks Use Halane a widely used source of chlorine is useful for cleaning and sanitizing high purity water treatment equipment This is an oxidizing cleaning solution which is effective primarily as a biocide against biofouling and secondarily a cleaner against organic fouling Due to its oxidizing power this cleaning solution should be used infrequently and the directions for its use followed closely rev 1 1 Page 11 25 Instruction 4 Peracetic Acid Hydrogen Peroxide Solution Recirculation Mild Oxidizing Sanitization Cleaning e Drain the cleaning skid and E Cell skid e Make up 25 L per Stack of peracetic acid 0 04 hydrogen peroxide 0 2 sol
22. ling and metallic scaling The table below summarizes the main steps that are performed for each procedure These steps are provided in detail in subsections which follow Ke elas fetales pr ls Procedure Regen Regen Rinse Santize Rinse Santize Rinse Instruction 3 AorB AorB Instruction 5 Instruction 6 Regen Rinse Regen Rinse instruction Regen Regen Notes Regen Brine Santize Caustic Santize Instruction 4 A or B A or B 1 The cleaning procedures are written for an E Cell System containing a single Stack For larger systems scale up proportionally Maintain chemical concentrations by multiplying all water and chemical amounts by the number of Stacks 2 E Cell System cleaning requires up to 8 hours per cleaning procedure 3 After cleaning the E Cell Stacks must be regenerated except Procedure 1 Regeneration requires up to 16 hours rev 1 1 Page 11 23 The Long Term Shutdown procedure must be followed if the E Cell System is to be down for more than three days 11 22 Safety 1 Avoid contact with Halane 1 3 Dichloro 5 5 dimethyl hydantoin sodium hydroxide peracetic acid hydrogen peroxide and hydrochloric acid as these are corrosive Hydrogen peroxide is an oxidizer 2 Depressurize all process lines to avoid high pressure chemical spray 3 The E Cell System operates at high voltage Before performing any maintenance
23. nless you understand the contents of this manual and have received training Serious injury may occur if the procedures in this manual are not followed The E Cell Stack operates under pressure above atmospheric and or vacuum below atmospheric Review the safety procedures of this manual Air scouring is not applicable to E Cell Stacks Air scouring will not aid in cleaning or removing blockage of E Cell Stacks Any disassembly of this E Cell Stack loosening or removal of retaining bolts or other improper handling or use of this E Cell Stack may cause severe personal injury All personnel must be trained on the hazards of working with chemical cleaning solutions Rubber gloves full rubber suits full face shields and goggles must be used when exposure to acid caustic oxidizers or any other chemicals is a possibility Install flange guards on all chemical lines Electrical Shock Hazard The E Cell Stack contains dangerous high voltage when it is energized Lockout the dc power supply before working around the E Cell Stacks Direct Current DC Used with V or A to indicate DC voltage or current or with On or Off symbols rev 1 1 Page 2 3 POST THIS WARNING PAGE ON YOUR E CET I SYSTEM Warning To Prevent Stack Damage WARRANTY MAY BE VOIDED IF THE FOLLOWING PRECAUTIONS ARE NOT FOLLOWED Blockage or interruption of flow will damage stacks If stacks are powered electric
24. pm 0 57 m3 h Minimum flow 15 O 6 7 gpm 1 52 m3 h Maximum flow See section Concentrate Bleed Stream for information on recovery and feedwater hardness Note The feed water to the E Cell Stack must be RO permeate or equivalent rev 1 1 Page 3 5 3 2 PRODUCT WATER SPECIFICATIONS The E Cell Stack will produce 16 MOhm cm water MK 2E MK 2Mini MK 2MiniHT or 10 MOhm cm MK 2Pharm MK 2PharmHT provided the feed water meets the Feed Water Specifications and the system is operated according to the Operating Instructions AA SALT SPECIFICATIONS Proper salt selection for brine injection is critical in avoiding long term problems with scaling and fouling The specifications for sodium chloride are as follows Sodium Chloride dry basis gt 99 80 Ca and Mg as Ca lt 0 05 Copper lt 0 5 ppm Iron as free Fe 5 0 ppm Heavy Metals as Pb 2 0 ppm Note 1 Any salt additive except yellow prussiate of soda sodium prussiate at up to 15 ppm in the salt may contribute to scaling and will void the warranty 2 Analytical grade salt may not meet this spec and is very expensive Several food grade salts are widely used in the food industry and are less expensive than Analytical grade 3 4 E CELL STACK OPERATING PARAMETERS Parameter Range Product Flow MK 2E MK 2Pharm MK 2PharmHT 7 5 to 20 0 gpm 1 70 to 4 54 m3 h MK 2Mini MK 2MiniHT 2 5 to 6 7 gpm 0 57 to 1 52 m3 h Feed Temperature 40 to
25. re as follows 1 Regularly inspect terminations for tightness and proper connection 2 Isolate any faulty electrical part prior to repairing or replacing it 3 Do not disconnect the power cable to the E Cell Stack with the DC power ON rev 1 1 Page 5 8 5 1 E CELL STACK MAXIMUM POWER REQUIREMENTS INPUT INPUT MAX VOLTAGE CURRENT POWER 100 600V 5 2 OPERATING CURRENT In order for the E Cell Stack to produce high quality water the current flow must be sufficient for the ionic load in the feed water In general more current is required as the ionic load increases More current is also required for silica removal 6 MECHANICAL AND HYDRAULIC Do not adjust the bolts on the E Cell Stack side and end plates as tampering may result in permanent damage to the E Cell Stack and voids the warranty Care must be taken to protect against water hammer Feed Water pressure should never exceed 100 psi 6 8 bar rev 1 1 Page 6 9 7 RECEIVING INSTALLATION 7 1 RECEIVING Inspect each E Cell Stack for shipping damage and then replace the packaging material The Stacks should remain in the packaging material until they are to be installed Any shipping damage must be reported to the shipper and E Cell within 5 days to validate claim 7 2 LIFTING There are lifting lugs at the top of the E Cell Stack allowing the use of a forklift or other mechanical device to move the E Cell Stack See specification
26. system and help identify any problems as early as possible The following parameters should be recorded at least once a day e Dilute Feed Pressure psi bar e Rectifier Voltage volts e Concentrate Inlet Pressure psi bar e System Current amps e Dilute Outlet Pressure psi bar e Concentrate Outlet Pressure psi bar e Product Resistivity Mohm cm e Pump Discharge Pressure psi bar e Concentrate Conductivity uS cm e Concentrate Bleed Flow gpm m3 h e Feed Conductivity uS cm e Concentrate Flow gpm m3 h e Electrode Flow gpm m3 h e Product Temperature F C e Dilute Flow gpm m3 h e Concentrate Temperature F C The following parameters should be recorded on a weekly basis e Feed Hardness ppm e Feed CO ppm e Feed Silica ppm Sample Operating data log forms are located at http www ecell com The GEWPT E Cell group developed the Field Monitoring Spreadsheet that automatically normalizes data and produces graphs similarly to RO operating data normalization programs The spreadsheet helps to determine cleaning needs and gives early warning of potential problems and is available at http www ecell com rev 1 1 Page 10 21 11 PREVENTATIVE MAINTENANCE 11 1 GENERAL Maintenance personnel must exercise extreme caution as any leaking water may be electrically charged Check high voltage connection and grounding wires are tight every 3 months Do not externally clean E Cell Stack usin
27. t 0 5ppm hardness as CaCO3 or gt 0 5ppm silica or failure to meet any feed specifications can damage the E Cell Stacks unless special precautions are being taken Regular acid cleaning and RO permeate softening may be required e For systems with a brine pump the quality of the salt must be carefully checked The salt must be of the special type listed in the E Cell Owner s Manual otherwise the stacks can be irreversibly damaged if run for extended period e Plastic fittings and nozzles are not repairable Handle with care rev 1 1 Page 2 4 3 SPECIFICATIONS 3 1 FEED WATER SPECIFICATIONS Constituent Units Feed TEA ppm as Caco As calculated by E Calc pH 5to9 Hardness ppm CaCO SESCH Silica reactive ppm 0 5 Minimum to Nominal product flow Silica reactive ppm lt 0 383 Maximum product flow TOC ppm lt 05 Total chlorine ppm lt 0 05 Fe Mn H2S ppm lt 0 01 SDI 15min lt 1 0 Oil amp Grease None detectable Turbidity NTU 1 0 Oxidizing agents None detectable Colour APHA 5 TEA MK 2E ppm as CaCO 25 15 gpm 3 4 m3 h product flow Nominal flow lt 48 8 7 5 gpm 3 4 m3 h Minimum flow lt 15 20 gpm 4 5 m3 h Maximum flow TEA MK 2Pharm amp 26 15 gpm 3 4 m3 h Nominal flow PharmHT 55 Q 7 5 gpm 1 7 m3 h Minimum flow 20 20 gpm 4 5 m3 h Maximum flow TEA MK 2 Mini amp 25 5 gpm 1 14 m3 h Nominal flow MIniHT 49 2 5 g
28. that they remain moist 4 After long term shutdown E Cell Stacks may require regeneration Regeneration will require approximately 8 to 16 hours rev 1 1 Page 9 16 10 OPERATING INSTRUCTIONS 10 1 FLOW RATES There are four separate flow streams on the E Cell System each with a distinct range and purpose 10 1 1 Dilute Stream Range 7 5 20 0 gpm 1 70 4 54 m3 h per MK 2E MK 2Pharm or MK 2PharmHT Stack 2 5 6 7 gpm 0 57 1 52 m3 h per MK 2Mini or MK 2MiniHT Stack The Dilute stream is the process water that is purified It is the primary source of cooling water for the Stack If the Stack is operated at less than minimum Product flow localised heating will occur inside the Stack resulting in damage and external leaks 10 1 2 Concentrate Stream Range 1 5 5 4 gpm 0 34 1 23 m3 h per MK 2E MK 2Pharm or MK 2PharmHT Stack 0 9 2 25 gpm 0 18 0 51 m3 h per MK 2Mini or MK 2MiniHT Stack The Concentrate stream is the collecting point for all the ions removed from the Dilute stream While this stream has a flow range the flow rate itself is never set only monitored The Concentrate inlet and outlet pressures must be less than the Dilute pressures therefore the Concentrate inlet and outlet pressures are set in order to obtain correct pressures first and flow rate second The Concentrate flow rate is monitored to track the E Cell Stack s performance If the electrical resistance of the E Cell Stack is too high current
29. the absence of upsets At feed hardness levels gt 0 1 ppm the recovery is reduced to 90 and salt is injected into the Concentrate loop as shown in the table above Periodic cleanings are required Recovery ratios are provided because the amount of Concentrate Bleed required is dependent on the feed water hardness the Dilute flow and the Electrode flow rates as Dilute flow increases the amount of hardness entering the E Cell Stack also increases rev 1 1 Page 10 18 Dilute Product Flow Recovery x100 Dilute Product Concentrate Bleed ElectrodeOutlet Flow Therefore Dilute Product Flow Recovery Concentrate Bleed Flow X 100 ElectodeOutlet Flow Dilute Product Flow Example For a system with lt 0 1 ppm of hardness in the feed water 25 gpm Dilute Product flow and 0 5 gpm Electrode Outlet flow what is the minimum Bleed flow rate 25 Concentrate Bleed Flow E x100 05 25 Therefore the minimum Concentrate Bleed Flow 0 8 gpm The Concentrate Bleed is usually higher quality than the RO feed water so it is usually recycled to the RO inlet This improves the overall E Cell System recovery to about 98 10 1 4 Electrode Stream Range 0 25 0 40 gpm 60 90 l h The Electrode stream flows over the electrodes This stream cools the electrodes and removes any gases produced in the chambers Due to the presence of H2 O2 and possibly Cl gas in this stream it must be sent to a vented drain Some of the
30. tion 7 Cleaning Procedure 7 Halane or Peracetic Acid Sanitizing and High pH Sanitizing Halane a widely used source of chlorine is useful for cleaning and sanitizing high purity water treatment equipment Peracetic acid 0 04 hydrogen peroxide 0 2 performs similarly using a different chemical species Due to their oxidizing power these cleaning solutions should be used infrequently Cleaning Procedure 6 Hydrochloric Acid and Halane or Peracetic Acid Sanitizing Where hardness or other metallic scale is present along with heavy biological fouling an acid cleaning step is added to the beginning of the procedure Halane a widely used source of chlorine is useful for cleaning and sanitizing high purity water treatment equipment Peracetic acid 0 04 hydrogen peroxide 0 2 performs similarly using a different chemical species Due to their oxidizing power these cleaning solutions should be used infrequently For severe biological fouling a high pH step is added to the procedure for improved efficiency LO ct E o IdeamngSetup InstructionS instruction6 O nstruction 2 Instruction 7 Cleaning Setup Instruction 1 Instruction 6 Instruction 5 Instruction 6 Instruction 3 or Instruction 4 NOT BOTH Instruction 5 Instruction 7 LO er E rev 1 1 Page 11 28 Cleaning Procedure 8 Hydrochloric Acid and Halane or Peracetic Acid Sanitizing and High pH Sanitizing
31. ution 0 25 L of a commercial solution such as Minntec Minncare Henkel Ecolab Oxonia Active Diversey Divosan or FMC Flocide in 25 L of water e Recirculate the peracetic acid hydrogen peroxide solution through the Dilute Concentrate and Electrode loops for 2 hours o The E Cell system will run with flow ranges as during normal operation using the Concentrate pump but with no current applied to the Stacks Use Peracetic acid 0 04 hydrogen peroxide 0 2 performs similarly to halane using a different chemical species It should also be used only when necessary Instruction 5 Sodium Chloride Solution Recirculation e Drain the cleaning skid and E Cell skid e Make up 25 L per Stack of NaCl 5 solution e Recirculate the NaCl solution through the Dilute Concentrate and Electrode loops for 10 minutes o The E Cell system will run with flow ranges as during normal operation using the Concentrate pump but with no current applied to the Stacks Use To bring the Stack ion exchange resin into the exhausted sodium and chloride forms in preparation for the next cleaning step or for regeneration It also assists in cleaning by displacing some contaminant ions from the resin Instruction 6 Water Rinse e Drain the cleaning skid and E Cell skid e Fill the cleaning tank with 25 L per Stack of RO or better quality water e Briefly recirculate the water and then drain the cleaning skid and E Cell skid e Repeat the water rinse steps onc
32. ve is closed and the Concentrate Outlet pressure is too high i e Cout Pressure is greater than or equal to Dout Pressure slowly close the Concentrate Make Up Valve The Concentrate Outlet pressure will start to decrease Once it is at least 5 psi 0 35 bar less than the Dilute Outlet pressure stop and check the inlet pressures The Concentrate Inlet pressure is probably too low Correct this by opening the Concentrate Inlet Valve Continue to make small adjustments to the Concentrate Make Up and Concentrate Inlet Valves until the Concentrate stream is at least 5 psi 0 35 bar less than the Dilute stream Ensure that Concentrate flow is within the correct range see section Operating Instructions If it is not continue to make small stepwise adjustments to Concentrate Inlet and Concentrate Bypass valves until Concentrate pressures and flow are in the correct ranges Open the Electrode Outlet Valve to achieve nominal 0 35 gpm Stack 80 l h Re adjust Concentrate Inlet Valve again if the pressure difference between Concentrate and Dilute Feed is not at least 5 psi 0 35 bar Set Concentrate Bleed Valve to achieve the required recovery The recovery rate is calculated according to the recovery formula explained in the section OPERATING INSTRUCTIONS Concentrate Bleed Stream Once Recovery is known Bleed Flow can be calculated from the definition of recovery given by the formula in that section Also Bleed Flow is calculated by E Calc Not
33. w rate 7 5 20 0 gpm 1 70 4 54 m3 h per MK 2E MK 2Pharm or MK 2PharmHT Stack 2 5 6 7 gpm 0 57 1 52 m3 h per MK 2Mini or MK 2MiniHT Stack rev 1 1 Page 8 13 HU P bat E2197 09 554 11 12 13 Once water flows continuously through the Concentrate Bleed no bubbles prime the Concentrate Pump see pump manufacturer s instructions in Vendor Data 8 2 8 Establish Concentrate Electrode and Dilute Flow Throttle Concentrate Inlet Valve so that it is 10 2096 open Confirm the Concentrate Pump Suction Valve is open Set the Concentrate Pump Discharge Valve 2596 open Close the Concentrate Bypass Valve Confirm Concentrate Make Up Valve is open Bump the Concentrate Pump by quickly turning the hand switch to Hand and back to Off If the pump does not operate check that the disconnect switch on the rectifier is in the ON position Confirm the pump rotation if incorrect a qualified electrician should swap two of the leads to change the pump rotation Start the Concentrate Pump by switching it to Hand Open the Concentrate Pump Discharge Valve 10096 Open the Concentrate Bleed Valve to attain approximately 1096 of Product flow Slowly adjust the Concentrate Inlet Valve until the Concentrate Inlet is at least 5 psi 0 35 bar less than the Dilute Feed pressure If the Concentrate Outlet pressure is zero open the Concentrate Bypass Valve in order to increase it above zero If the Concentrate By Pass Val
34. will not flow through the Stack The Concentrate stream can be used to adjust the Stack s resistance in order to increase the current flow During operation ions from the Dilute stream are collected in the concentrate stream The Concentrate is recycled through the E Cell Stack to further increase the Concentrate conductivity and thereby decrease the E Cell Stack s resistance Recycling the Concentrate through the Stack also allows the system to operate with high Concentrate flow rates The high flows lead to high velocities through the Concentrate chambers decreasing the opportunity for scaling The minimum Concentrate flow rate is 1 5 gpm 0 34 m3 h for MK 2E MK 2Pharm and MK 2PharmHT Stacks and 0 9 gpm 0 18 m3 h for MK 2Mini and MK 2MiniHT Stacks If the Stack is operated at less than minimum concentrate flow the stack will scale and localized heating will occur inside the Stack resulting in damage and external leaks rev 1 1 Page 10 17 In order to prevent the Concentrate stream from exceeding the solubility limits a small amount of Concentrate is sent to drain This water is replaced with Dilute feed water through the Concentrate Make up valve The amount of Concentrate Bleed required is dependent on the Recovery required which is itself dependent on the flow rates and the feed water hardness level For more information on Recovery and Concentrate Bleed see the Concentrate Bleed section below The conductivity of t
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