Monday, November 28, 2011

Validatable Water System for New Jersey Pharmaceutical Company Shipped

We were recently asked to provide a DI water system for a central NJ Pharmaceutical company. They required a small amount of water for a batching operation, 50 – 60 gallons per batch 3 to 5 batches per day. Their requirements were that the water would have to meet USP specifications and that the system would need to be validatable.

Reskem Water treatment and recirculation system on skid mounts
Res-Kem Skid-Mounted Water Treatment and Recirculation System
Being Prepared For Delivery
This was a perfect fit for one of our portable skid mounted, pre-plumbed and wired delivery systems. The system fabricated offered 5-micron pre filter cartridge, gallon totalizing meter, SDI exchange tanks, 1-micron resin trap filter cartridge to a 125-gallon storage tank complete with vent filter, spray ball assembly, and 3-way level control. The water would then return to the skid by way of a continuous duty recirculation pump where it would continue through a flow indication meter, bacteria control ultra violet, exchangeable polishing resin tanks and 0.20 micron absolute final filters before returning to the storage tank.

A storage tank made out of polypropylene that has a spray ball assembly being prepared for delivery
125 Gallon Sterile-Vented Polypropylene Storage Tank
With Spray Ball Assembly Being Prepared for Delivery
The customer also included an optional temperature control dump valve and resistivity monitor with two sensors. All this is controlled by an AB-Micrologx 1200 PLC. The entire skid with storage tank takes up less than 16 square feet of floor space and stands less than 6 feet in height.

To complete the package was all validation documentation to insure a seamless and quick turn over at start-up. This included P&ID, electrical schematics, and data required for IQ (Installation Qualification), and OQ (Operational Qualification).  This package was provided as both a hard copy and on a CD.  
A P&ID for a Reskem recirculation skid
P&ID For Res-Kem Recirculation Skid
Also, as an economical advantage, this system is not only portable but also expandable with very little expense so it will grow as the business grows.

Friday, November 18, 2011

Reduce Your Backwash Flow or Lament "Why is my ion exchange resin in the drain?"

It is that time of year.  You must reduce your backwash flow in the Fall or you will find your ion exchange resin in the drain or waste treatment plant.

Why do I need to reduce my backwash flow rate?
If the backwash rate for an ion exchange system is set when the water is warm, the flow rate will be too high when the water temperature is cold.  Anion resins are more susceptible to this problem because their densities are lower than cation resins.  Your ion exchange supplier should have curves of each resin in their literature.

A chart that shows an example of backwash flow rates
Example of Backwash Flow Rates and Bed Expansion Chart
Purolite C-100
For example, if a water softening system and therefore the tank are designed for a 50% bed expansion at 77F, the backwash flow rate will be about 6.5 gpm/sq ft for Purolite C-100 cation exchange resin.  If the temperature of the water decreases to 41F, the bed will expand 120% at that same 6.5 gpm/sq ft sending most of the resin down the drain.

Please note, each resin will have a different backwash rate, so look in the manufacturer's bulletins for the correct value.

How do I prevent this from happening?
  • If you have a backwash valve with a position stop, decrease the flow rate to the correct value at the colder operation temperature. 
  • If you have a backwash controller with rubber inserts, remove and plug enough holes to decrease the flow rate to the correct value at the colder operation temperature.
  • Some of the next-to-limitless flow controls and flow inserts that Res-Kem offers
    Some of the Numerous Flow Controls and Flow Inserts Offered by Res-Kem
  • Install a resin trap in the backwash line of the system.  If there is any media carry-over, it will be trapped, hence the name.

A resin trap that Res-Kem offers to keep resin from harming the environment
Res-Kem Manufactures Resin Traps for 2", 3" and 4" Piping to Prevent Resin and
Other Media From Contaminating Downstream Equipment
Need Help?:
Contact Res-Kem if you need help determining what needs to be done or to have us service you equipment.

Need Technical Information?
Flo-Controlet Flow Control Brochure Page 1 and Page 2

Tuesday, November 15, 2011

3D CAD Drawings for Condensate Polishers for University in Massachusetts

In order to speed installation of the condensate polishers we recently shipped to Massachusetts, Res-Kem was asked to provide 3D CAD files for the condensate polishers.  Here are some screenshots of these drawings.
A three dimensional representation of a Triple Condensate Polisher
Solidworks 3D CAD drawing of Triple Condensate Polisher
Why use 3D CAD?
Given the complexity of the installation, tight dimensions and tight timeline, the 3D drawing helps the mechanical contractors understand how the condensate polisher is assembled and needs to be installed.  Also, prior to receiving the system, the contractor can bring piping to the equipment saving on site installation time. 

In addition to the standard AutoCAD and Solidworks files we sent to the customer, we sent an executable file.  This allows anyone, with or without a CAD program, the ability to select any view and take dimensions off of the drawing.

A condensate polisher that can be used in your plant
Alternate view of 3D CAD drawing of Stainless Steel Condensate Polishers
Contact us for assistance sizing and selecting a condensate polisher for your plant.