Res-Kem Blog

Maximize Your Cost Savings With a Properly Sized Sodium Cycle Condensate Polisher

noreply@blogger.com (S Matson) — Fri, 25 May 2012 20:50:00 +0000

Res-Kem’s Process Engineer Kevin Preising discusses their Boiler Feedwater Checklist and the 15 questions that will help properly size a Sodium Cycle Condensate Polisher (and generate the most payback) for your steam plant. Please print out the checklist and follow along!

Dealkalizer Shipped to University in Massachusetts

noreply@blogger.com (T Dupnik) — Fri, 18 May 2012 19:00:00 +0000

A triple dealkalizer was shipped this week is the last major piece of equipment for a major steam boiler upgrade at a university in Cambridge, Massachusetts which included a new condensate polisher system Res-Kem provided, a deaerator and other major physical plant upgrades. The months between the polisher shipment and the dealkalizer shipment were filled with activity in the steam plant.

Triple Dealkalizer System Being Prepared for Shipment

The shipment of the dealkalizer had to wait several months because the condensate polisher had to be moved into place, installed and started up. Once this was completed, the deaerator was delivered and required installation and start up. After that, the entire revamped boiler treatment system had to be tested, operating correctly and then operators needed to be trained. Once everything was proven out to the satisfaction of the university, the old condensate polisher could be scrapped and the piping prepared for our dealkalizer which will be placed in the same location where the CP was.

What a dealkalizer does:	A dealkalizer removes Alkalinity which breaks down in the boiler and generates CO2 and carbonic acid (H2CO3) in the condensate. The removing of CO2 and Carbonic acid reduces corrosion rates within the condensate piping
Inlet alkalinity:	Average inlet M-Alkalinity- 40 ppm- 50 ppm
Savings the customer wants to achieve:	• Reduced Corrosion of steam condensate return piping • Lower return condensate iron levels in boiler feedwater and cleaner boiler tube surfaces • Lower Operating expenses on fuel with cleaner boiler tubes • Eliminating alkalinity via the dealkalizer allows for higher boiler cycles of concentration and lower fuel costs
Flow Operating Conditions:	Typical: 140 gpm typical Peak: 200 gpm Minimum: 40 gpm
System Configuration:	• Triple 42 " diameter X 72" ASME Code fiberglass tanks • Each tank has a front mounted/supported Pentair Fleck 3900 valve with NXT controller • All Interconnecting pipe is Schedule 80 PVC piping • Each tank is individually skid mounted
Control Valves:	Multi-Port Fleck 3900 valves side mounted and supported via welded steel frame
System Operation:	Progressive Flow and Demand Flow operations
Added Features:	Contacts on the Fleck valve indicate to the DCS that the unit is in operation, standby, or regeneration

Additional Information:
Technical bulletin for Res-Kem's dealkalizer equipment

Improving Efficiency of Water Softeners at a Hospital

noreply@blogger.com (T Dupnik) — Mon, 23 Apr 2012 19:50:00 +0000

A customer found they could reduce the salt and water costs of regeneration by 63% by having our service person diagnose the problems they were having and make changes to the system.

Situation:A hospital customer has a 20 cubic foot water softener used for domestic water. The system was designed for run length of of 20,000 gallons between regenerations, but recent records indicate the run length has reduced to 10,000 gallons. The hospital demand is approximately 10,000 gallons per day. The following is the cost information:

Water and Sewer Cost - $4.00/1000 gallons
Salt Cost - $0.05/lb

Findings:
After inspection of the unit and analysis of resin samples, several problems were found:

The softener had 7 cu ft missing in the softener
The resin was fouled with iron
The regeneration cycle needed to be adjusted

Changes:
The following changes were made:

7 cubic feet of cation softening resin was added to the softener
The resin was cleaned to remove iron and a preventative maintenance program will maintain clean resin in the future
The regeneration cycle was changed to the design conditions

Results:

The following are the benefits the customer realized by making the recommended changes:

The number of regenerations dropped from 365 to 182 per year
The salt use per regeneration dropped from 180 lbs to 120 lbs.
The water use pre-regeneration decreased from 2590 gallons to 2090 gallons

Calculations:

Cost	Calculations	$/year
Salt Before	(180lb/regeneration)($0.05/lb)(365 regenerations per year)	$3,285/year
Salt After	(120lb/regeneration)($0.05/lb)(182 regenerations per year)	$1,092/year
Salt Savings		$2,193/year

Water Before	(2590 gallons/regeneration)($4.00/1000 gallons)(365 regenerations per year)	$3,781/year
Water After	(2090 gallons/regeneration)($4.00/1000 gallons)(182 regenerations per year)	$1,522/year
Water Savings		$2,259/year

Total Savings		$4,452/year

Water Reuse From Wastewater Using RO

noreply@blogger.com (T Dupnik) — Mon, 16 Apr 2012 17:10:00 +0000

Often we are asked to help with water re-use project. From their research, prospective customers are often interested in using an RO system. They want to take advantage of the key features which make RO a great technology for treating water entering their plant for process applications:

The RO membrane is barrier between the treated and untreated water
Reverse osmosis reduces the TDS (Total Dissolved Solids)
RO systems and membranes are a robust, proven technology

These advantages have been quantified and defined when an RO system is desalinating water and treating municipal/well water. More information is required before any RO is placed on a process waste stream. Often a pilot is required. Our parent company, Ecolab, has extensive experience with water treatment and reuse applications, but more information than a standard water test is needed to determine whether RO has a chance of working.

When looking at a water re-use project from wastewater, regardless of where the water re-use potential location is, it is essential that the water quality is considered both from a physical /chemical perspective but also from a biological perspective. What that means is analysis for parameters such as BOD / COD,( Biological Oxygen Demand / Chemical Oxygen Demand), turbidity , FOG ( Fats, Oils & Grease), NH3 /TKN ,( ammonia /total Kjeldahl nitrogen), NO3 and Total P as well as TSS ( Total Suspended Solids ) and conductivity or TDS( Total Dissolved Solids) should be added to the more typical water analysis list. If your facility is a food and beverage plant, a microbiological assay should be done.

NOTE- most of these tests require special sampling methods and handling. The WHO (World Health Organization) has an excellent paper on the subject "Water Quality Monitoring - A Practical Guide to the Design and Implementation of Freshwater Quality Studies and Monitoring Programmes". Look at pages 17-18.

Additional Information:
Definition of Waste water quality parameters
The Kjeldahl test method used to determine the nitrogen concentration in a waste stream
Standard Methods For the Examination Of Water and Wastewater

Chloramine Removal With Catalytic Carbon

noreply@blogger.com (michael urbans) — Tue, 03 Apr 2012 18:50:00 +0000

Is your carbon under attack? Have you chosen the correct carbon for chloramine removal? What carbon makes the most effective final barrier against chloramines?

Why use chloramination?Let's face it everyone, they're not making any more fresh water on this planet. Our fresh water is under continuous attack from man made substances and biological bad guys. To combat these contaminates, our municipalities are continually challenged to find the "right" treatment. For instance, good old chlorine was effective to combat bacteria and most disease. However, as our water systems with miles of pipe kept growing, chlorine's "staying power" was found to be less effective at the end of the line. And worse yet, chlorine would complex with organic matter (pipe sludge) or natural algae, to create disinfection by-products (THM's). Enter Chloramine. Some science guru dreamt up the idea that chlorine was more effective if they mixed in some Ammonia. Yes, ammonia. Chlorine+Ammonia = Chloramine

As you might imagine, chloramine wasn't the magic bullet bio fighting miracle. Needless to say, Chloramine, is better off in the street pipes than in you or in your ingredients. Ok? Now what? Since the invention of chlorine, man used activated carbon as the final barrier to remove it. Most activated carbon is manufactured from coal or coconut shells. Chloramine removal turned out to be a much trickier challenge. Here's why: Most drinking water is at pH 7 or above. At pH 7 chloramine forms into a monochloramine. Monochloramines are highly stable by nature making them very difficult to remove with traditional activated carbons. Calgon discovered if you manufacture carbon with catalytic functionality, it will remove the chloramine. Here's how: traditional carbon would do an excellent job of removing the chlorine portion, but leave a significant amount of ammonia. Catalytic enhancements to traditional carbon allowed the carbon to retain more oxygen. The oxygen acted as the needed catalyst to breakdown the ammonia. Simple 'eh?

Coconut vs Coal based carbon
YES you have a choice. This is America. It comes down to this: Our real world results have confirmed the coconut shell based catalytic carbons the clear winner.

Coconut vs Coal Chloramine Removal Comparison
from Jacobi CX-MCA Technical Paper

I speculate that coconut shell carbons have a micro-pure structure that allows them to retain more oxygen, thus be more catalytic. Also, scientific proof tells us that the coconut shell carbon is physically harder than coal carbons. When dechlorinating, carbon gives up a structural molecule. Coconut shell's strength gives it an advantage in the long run.

For Additional Information:
If you are really into the technical wizardry, read what the really smart folks wrote:
Technical Bulletin for Jacobi Aquasorb CX-MCA Catalytic Coconut Carbon
Technical Paper "Treatment for Monochloramine Using Activated Carbon" by Jacobi Carbon

DI System Shipping to Washington Chemical Plant

noreply@blogger.com (T Dupnik) — Fri, 30 Mar 2012 19:28:00 +0000

Shipping today is a two bed (cation ion exchange tank followed by an anion ion exchange tank) demineralizer for a chemical plant in Washington State. This unit is a DI60072 and will be used in parallel with several other older systems currently installed at the same plant to increase treated water capacity.

150 gpm Demineralizer Showing NEMA 4X Control Panel with Panel View 300 HMI

The system will use the existing bulk acid and caustic for regeneration of the cation resin and anion resin respectively.

150 gpm Demineralizer Compact Design of Piping

System Design:

Normal Service Flow Rate:	150 gpm
Maximum Service Flow Rate:	230 gpm
Vessel Size:	60" x 72" Diameter x Straight side
Volume of Cation (SAC) Resin	66 cu ft
Volume of Anion (Type 1) Resin	77 cuft
Cation Vessel Internals:	Header Lateral Design PVC Schedule 80
Anion Vessel Internals:	Header Lateral Design 316L SS Schedule 10
Automatic Valves:	Butterfly valves 316L SS disc with Air to Open Spring to Close Actuators
Controls:	Allen Bradley Micrologix PLC Panelview 300 HMI NEMA 4X FRP panel
Instrumentation:	Signet Flow meter Totalizer Thornton Conductivity Meter

Additional Information:
For our complete demineralizer/deionizer product line.
For help sizing a DI system, please contact us.

Downloadable Catalog of Water Treatment Equipment Updated

noreply@blogger.com (T Dupnik) — Fri, 23 Mar 2012 12:47:00 +0000

For 2012, we updated our downloadable industrial water treatment catalog. (Given the number of equipment choices we provide, the catalog file is very large, so please be patient during the download.)

Res-Kem's Industrial Water Treatment Equipment Catalog for 2012

In addition to the updated XL, CL and ML Series RO system bulletins list in my previous post, we have updated the two bed demineralizer sections of our catalog to include all of the standard sized DI systems up to 96" in diameter.

To many water treatment system choices? Contact us for help!

Industrial RO System Information Updated

noreply@blogger.com (T Dupnik) — Fri, 16 Mar 2012 13:55:00 +0000

Bulletins on the RO systems Res-Kem provides have been updated. These bulletins include the most up to date standard and custom features of the XL, CL, and ML series RO systems.

Reverse Osmosis Systems
Type	Single System Capacity*	Controller	File
Res-Kem XL RO Systems	9,650-698,400 GPD (6.7-485 GPM)	Allen Bradley PLC with Panelview Touchscreen HMI	Res-Kem XL RO Brochure
Res-Kem CL RO Systems	3,150-22,300 GPD (2.1-15.5 GPM)	Allen Bradley PLC with Panelview Touchscreen HMI	Res-Kem CL RO Brochure
Res-Kem ML RO Systems	1,050-8,380 GPD (0.7-5.8 GPM)	Digital Microprocessor	Res-Kem ML RO Brochure
* If you have required flow rates above those listed in each category, multiple units can be used.

Res-Kem XL Series RO Systems

Contact us for Help:

Sizing a new RO System
Maintaining an existing RO System
Renting a Mobile or Skid Mounted RO System
Getting Exchange DI Services after an RO System

Condensate Polisher "Portfolio" Added

noreply@blogger.com (T Dupnik) — Wed, 14 Mar 2012 14:18:00 +0000

A sodium cycle condensate polisher "portfolio" page was added to the Res-Kem website. As you have seen, I have used this blog to highlight the systems we have designed, manufactured and shipped to companies throughout North America. Given the large number of systems we have manufactured, a consolidated list of these systems would be helpful rather than hunting through the blog.

As you will see, Res-Kem has a base standard design that we have customized to meet the requirements of their facility or process. Contact us if you want more information on a specific system you see or one you are contemplating. I will add detailed information on each system in the coming weeks. Also, I will continue to update this page with new systems we have sold.

Water Softener vs. Condensate Polisher – Knowing the Differences Can Help you "Get Greener"

noreply@blogger.com (S Matson) — Mon, 12 Mar 2012 15:46:00 +0000

Many companies are on a constant quest to run their business in the most energy-conscious, money-saving way possible. For those whose operations involve a low-pressure boiler system environment, investing in a condensate polisher is one of the easiest ways to “get greener” through energy efficiency and dollar savings.

In most every boiler plant, cold water softeners are used to treat boiler water makeup. What’s less common is the use of a condensate polisher which treats condensate return for resuse as boiler feedwater. There are several differences between a water softener and a condensate polisher. Let’s look at a few:

Water Softener vs. Condensate Polisher
Installion – a water softener is typically installed “upfront” with the boiler system in order to meet the ASME/manufacturer’s water quality specifications. A condensate polisher is often an “add-on” to an existing boiler system once steam traps, condensate piping, and condensate receivers age and form deposits (such as iron, copper, and magnesium) that cause thermal resistance to drop.

Materials of construction – water softeners are constructed of epoxy coated tanks or poly-lined FRP tanks, with cast iron or PVC valves and black iron or PVC piping. Res-Kem’s standard condensate polisher systems are fabricated completely with stainless steel. This all stainless steel construction is the best material choice for safe operation over a long time.

Temperature & flow rate – condensate polishers are built to operate at a much higher temperature and flow rate. Where water softeners operate below 80 degrees F, polishers operate substantially above 120 degrees F. The higher temperature and flow rate allow a polisher to acts as both an ion exchange device AND filter, removing copper and iron oxides that cause scale buildup. This oxide removal is not possible with a water softener system, which act only as an ion exchange device with limited filtering capabilities.

Stainless steel surface preparation – condensate polishers are passivated. After fabrication, to further enhance the corrosion resistance of our stainless steel components, all of our welded stainless steel piping and tanks are passivated. This is an expensive, multi-step process which includes bead blasting and passivation, for the longest condensate polisher life.

So what do all these differences ultimately mean for a customer who invests in a condensate polisher?

1) Fuel savings – a condensate polisher saves fuel by allowing higher boilerwater cycles of concentration by reducing the Fe and Cu oxides that cause scale buildup. Fuel savings is also realized through the reuse of heat in the steam condensate.

2) Reduced chemical usage – because of the reduction of oxides and scale buildup in the steam loop, less investment is needed in internal boiler treatment chemicals that are used to remove buildup.

3) Longer and safer service life – a condensate polisher’s passivated, stainless steel construction ensures optimal operation for many years, with minimal routine maintenance. The typical life expectancy of a condensate polisher is 10-20 years.

Learn more about the customizable standard features and specifications of eight of Res-Kem’s recently manufactured condensate polisher models. Download our brochure today, then give us a call to see how we can help you “get greener” with more energy efficiency and more money in your pocket.

Condensate Polisher Product Bulletin Updated

noreply@blogger.com (T Dupnik) — Fri, 09 Mar 2012 20:11:00 +0000

Res-Kem has updated the features list of our standard condensate polisher product line because we had important ones which we did not tell anyone about!

For example:

All of the welded stainless steel piping and tank components have always used the expensive and necessary bead blasting and passivation, for long condensate polisher system life
All our stainless steel piping is welded per ASME Section IX
All our laterals use wedge wire screeening

Duplex Alternating 48" Condensate Polisher
with Optional Bray Valves

Stainless Steel Header & Wedge Wire Lateral Distributors
Installed Above
Stainless Steel Hub & Wedge Wire Laterals

Also, one common option customers have asked for is to provide stainless steel headers. For most multiple unit systems we have sold, we have provided the inlet, outlet, brine, sub-surface wash and drain headers. We needed to add this information to the bulletin as well.

Additional Information:
New Condensate Polisher Bulletin

Downloadable CP Checklist

Need help sizing a Condensate Polisher

400 gpm Multi-Media Filters Shipped to Brewery in Pennsylvania

noreply@blogger.com (T Dupnik) — Fri, 24 Feb 2012 12:43:00 +0000

Res-Kem shipped a dual alternating multi-media to a brewery in northeastern Pennsylvania. The each multi-media vessel has a design flow rate of 400 gpm and a peak flow rate of 510 gpm. The system filters all the municipal water entering the plant for all applications including brewing.

Dual 84" Diameter Multi-Media Filters

Design Features:

Two 84" diameter ASME code vessels rated at 100 psig. The internal coating is an FDA epoxy
Aquamatic diaphragm are used
External piping is Schedule 80 black iron pipe
Each filter is controlled using an Aquamatic 948 controller which backwashes on a time basis

Closeup of Multi-Media Filter Before Shipment

For additonal information:

Res-Kem's Multi-Media Filter System Bulletin
Res-Kem's Complete Media Filtration Product Line
Need technical assistance and/or system pricing?

Three Duplex 80 gpm Multi-Media Filters Ready for Shipment

noreply@blogger.com (T Dupnik) — Fri, 10 Feb 2012 15:33:00 +0000

Res-Kem is has delivered 20 of the 40 customized, duplex multi-media filters for mobile enhanced oil recovery trailers. The Res-Kem multi-media filters are sized to continuously produce 80 gpm of water to downstream equipment including steam generators. The trailers generate steam which is injected into wells to recover more oil. The system started out as one of our customizable standard duplex multi-media filters.

Three Duplex Multi-Media Filters Being Prepared for Shipment

We added the following features to meet the customer's requirements:

UV resistant tank coating for enhanced tank life
Welded Schedule 10 stainless steel face piping for corrosion resistance
Skid mounting on stainless steel frame
Custom configured inlet and outlet piping locations to minimze piping between other equipment on trailer
Bray butterfly valves with position indicators and limit switches
All valve solenoids and limit switches are wired to a single NEMA 4X stainless steel box to be interfaced with PLC which will control all equipment on the trailer
Resin trap on the product line of each filter to protect downstream equipment

For additonal information:

Res-Kem's Multi-Media Filter System Bulletin
Res-Kem's Complete Filtration Product Line
Res-Kem's other industrial water treatment equipment
For technical assistance and system pricing

Q&A on Condensate Polishers with Res-Kem’s Kevin Preising

noreply@blogger.com (S Matson) — Wed, 25 Jan 2012 14:44:00 +0000

While dirty condensate clean-up can be an energy buster in most processing plants, one cost effective solution is to polish contaminated condensate for re-use. Condensate polishers use a simple ion exchange technology that is easy to operate, easy to maintain and economical to use – less make-up water is required which leads to lower chemical and energy consumption.

Here is a brief Q&A video with Res-Kem’s Process Engineer Kevin Preising that addresses some of the most common questions about Condensate Polishers. Kevin touches on the following points:
• The difference between sodium condensate polishers and water softeners
• The life expectancy of a condensate polisher
• What plant utility services are required for condensate polishers
• Why a sub-surface wash is important
• The advantage of using a sample cooler
• The type of instruments on a condensate polisher

Watch it now!

New Two Bed Demineralizer Technical Bulletins

noreply@blogger.com (T Dupnik) — Wed, 18 Jan 2012 16:23:00 +0000

Res-Kem has a complete 2-Bed demineralizer product line designed for industrial water production. The standard tank sizes range from 18" to 96".

Two-Bed Demineralizer with
PVC Tank Coating and PVC Face Piping

These two-bed deionizers are designed for fully or semi-automatic production of water with a conductivity of less than 10 micro-ohms and feature:

Flow rates from 10 - 220 gpm and capacities from 140,000 - 2,200,000 grains.
Strong acid 8% crosslinked cation and type 2 strong base anion resins as the standard, with other resins available as an option.
Microprocessor based control system with conductivity monitor and flow sensor for regeneration initiation.
Electrical enclosures are NEMA 4XFG corrosion resistant fiberglass, which reduces maintenance costs.
PVC coated steel vessels depending on size and customer requirements.
Optional ASME code vessels.
Factory assembled and skid mounted for quick installation and minimum startup cost.
Schedule 80 PVC piping package including air operated true union ball valves are standard. Air or electric actuated ball or butterfly valves are available as an option.
Pressure regulators, rotameters and metering valves supplied for accurate and safe control of regeneration water and chemical introduction.
Internal distributors are corrosion resistant, designed for optimum efficiency and are fully supported where required.

Technical Bulletins:
The following are the standard system sizes available from Res-Kem:

DI18072	Dual 18-inch diameter demineralizer system
DI24072	Dual 24-inch diameter system
DI30072	Dual 30-inch diameter system
DI36072	Dual 36-inch diameter system
DI42072	Dual 42-inch diameter system
DI48072	Dual 48-inch diameter system
DI54072	Dual 54-inch diameter system
DI60072	Dual 60-inch diameter system
DI66072	Dual 66-inch diameter system
DI72072	Dual 72-inch diameter system
DI78072	Dual 78-inch diameter system
DI84072	Dual 84-inch diameter system
DI90072	Dual 90-inch diameter system
DI96072	Dual 96-inch diameter system

For further information, please contact Res-Kem or call 800-323-1983.

Elliptical Bolt & Yoke Manways

noreply@blogger.com (Mike Polito) — Thu, 12 Jan 2012 19:18:00 +0000

Res-Kem is a leading supplier of elliptical yoke and bolt manways for personnel access to pressure vessels. Res-Kem offers various sizes of these complete manhole assemblies or tank manhole covers, which can be used for industrial and commercial water treatment applications. They are the following:

· 11x15

· 12x16

· 14x18

· 18x24

Most of the manway requests we receive from callers are for replacement cover assemblies, or top assemblies. A top assembly consists of the following:

· cover

· (2) yokes

· (2) nuts & bolts

· gasket

We can also provide complete manway assemblies, which include all of the above, and the tank-welding ring. Tank welding rings, which are known as the tank opening, are 3/4" or 1" thick, with depths of 3", 4", 5" or 6". Typically, our customers specify the ring dimension. We can offer some assistance on the ring depth if we are given information on the tank shell diameter, and the thickness of either the shell or head.

When it comes to replacing an elliptical manway on an existing tank, the most important aspect is to provide the inside dimensions of the tank opening (which is the welding ring), so Res-Kem can properly quote the correct size cover. Measuring the depth of the opening will help us determine the correct length of the bolts that are needed. For example, if an opening measures 4" in depth, we will offer a bolt length 1" longer than the depth of the opening if the size of the manway is 11x15, 12x16, or 14x18. If the manway is an 18x24 size, we will offer a bolt length 2" longer than the depth.

We offer manways made of:

Carbon steel
304 stainless steel
316 stainless steel.

The manways come standard with a neoprene gasket rated for a max temperature of 170 ° Fahrenheit, or we can provide gaskets rated for temperatures over 500 ° Fahrenheit.

If you are not sure what size manway you require, you can review our product bulletin for assistance, email Mike Polito, or call us at 800-323-1983.

Condensate Polishing & Maintaining Quality Boiler Water

noreply@blogger.com (S Matson) — Tue, 10 Jan 2012 13:30:00 +0000

Maintaining proper boiler water quality can be both costly and complicated when faced with navigating ASME boiler water guidelines. One cost effective solution is sodium cycle condensate polishing. Simple to operate and maintain, condensate polishers have been proven to realize real savings relative to chemical and energy consumption and provide the ability to control
corrosion transport and condenser in-leakage.

Not sure if condensate polishing is a good fit for your needs? We’ve developed a Boiler Feedwater checklist to help. Click here to review the list or contact us and we’ll analyze your steam loop together.

Condensate Polisher Ready for Shipment to Chemical Plant in Louisiana

noreply@blogger.com (T Dupnik) — Tue, 20 Dec 2011 17:09:00 +0000

Res-Kem will be shipping a condensate polisher to a chemical plant in Louisiana in a two days. This system will be used to treat condensate to save water treatment chemical costs, identify process equipment leaks and will likely improve product quality of the chemicals they produce.

What is the problem?
The chemical plant uses steam in heat exchangers and jacketed process reactors. The steam condensate returns at about 20 ppm hardness 24/7. Recycling this high hardness condensate back into the boiler makeup water reduces the number of cycles of concentration possible and increases water treatment chemical usage. Given the number of heat exchangers and reactors, it has been difficult to determine where the leaks are coming from.

What is the system solution?
Working with a Res-Kem subject matter expert, a condensate polisher was selected to reduce the hardness in the steam condensate prior to being returned to the boiler makeup. A Hach SP-510 hardness analyzer installed on the treated water side of the CP will be used to determine when the polisher needs to be regenerated every two minutes process. A Hach APA-6000 will be used to measure the incoming value of the hardness during operation. By measuring and recording the water hardness and which process is operating, the plant engineers should be able to correlate which heat exchanger and/or reactor has the leak.

Single Condensate Polisher with Bray Valves and Sample Cooler

System Operating Parameters:
The new, single tank condensate polisher will treat up to 140 gpm and since the system uses a highly crosslinked cation exchange resin, the system will operate at a maximum of 185 F. As stated above, the Hach SP510 analyzer will take samples of the treated condensate every two minutes. When the treated condensate reaches 10 ppm a signal will be sent to the DCS in the control room. Depending upon the production schedule, regeneration of the condensate polisher start.

System Features:
Res-Kem has a customizable standard design for our condensate polishers from 20 to 66" in diameter with single to multiple tanks in parallel. All wetted materials of the polisher are manufactured in 304L and 316L stainless steel. The single mineral tank is an ASME-code vessel with a design pressure of 100 psig and test pressure of 130 psig. The valves are Bray butterfly valves with 316L wetted parts. Since we have a customizable standard design we easily accommodated the customer's company-wide standard of HYTORX actuators with position indicators.

Bray Valve with HYTORX-131 Actuator and Flow Control on Condensate Polisher

Optional Added Features:

Sample cooler-Required to operate the Hach hardness analyzers. The maximum operating temperature for these instruments is F. Also, the sample cooler insure accurate measurement of pH in the condensate. Without a sample cooler, the pH will be inaccurately high.
Hach SP510 Go/No Go hardness analyzer-This unit has multiple ranges which need to be selected when ordering
Hach APA 6000
Emerson HYTORX actuators

For Additional Help:

Water Softener Shipped to Food Flavorings Company in New Jersey

noreply@blogger.com (T Dupnik) — Tue, 13 Dec 2011 21:51:00 +0000

Res-Kem recently shipped an industrial water softener to a food flavorings plant in southern New Jersey. The water treated by the water softener is used to make steam to sterilize the raw plant material prior to extraction and extract the flavoring. The softener will be a replacement to an existing tank which has failed after 40 years of service.

System Operating Parameters:
Since most of the steam ends up in the plant matter and the extracted flavor ingredient, very little steam condensate is returned. This make the makeup flow very large. Each of the three softeners operate at 200 gpm and 80 psig. Because to the system's age, corrosion of the tanks and piping have become a maintenance nightmare.

Existing Industrial Water Softener

New System:
The new system is an 84" diameter steel vessel and is finished in an epoxy coated interior and exterior. The face piping is Schedule 80 PVC. The valves are Bray valves with Bray air-to-air actuators. The system is controlled by an Aquamatic 962 controller. At this point, regeneration will be initiated manually when production will allow. To handle the existing uneven floor, four jack legs were provided.

New Water Softener prior to Shipment to Food and Flavorings Plant

I Can't Believe It's Not A Water Sample!

noreply@blogger.com (michael urbans) — Thu, 01 Dec 2011 14:07:00 +0000

Holy Moses! It wasn't 1 week after my last blog on October 28th 2011 about receiving water sample in old pickle jars when I get a water sample in an used margarine container!

Water Sample Container Received by Res-Kem

P-L-E-A-S-E!. My disclaimer: "results not guaranteed for accuracy due to improper sampling container" Ok, the courtesy testing we do is of the non-critical, aesthetics only variety, however, I'm sure the old butter will skew my results. Now that the blue is leaving my face, please help a friend out and read my October 28th 2011 blog. Matter of fact, print it out and keep it in your shirt pocket or maybe tape it to the back door of your work van. Amen.

Validatable Water System for New Jersey Pharmaceutical Company Shipped

noreply@blogger.com (S C Barton) — Mon, 28 Nov 2011 21:34:00 +0000

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.

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.

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.

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.

For More Information:
Link to Modular Ultrapure Water Systems
Modular Ultrapure Water Systems Brochure
Service Deionization Information
Need technical help selecting a solution?

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

noreply@blogger.com (T Dupnik) — Fri, 18 Nov 2011 19:51:00 +0000

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.

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 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.

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?

Dow Ion Exchange Resin Information

Purolite Ion Exchange Resin Information

Sybron/Lanxess Ion Exchange Resin Information

Thermax Ion Exchange Resin Information

Flo-Controlet Flow Control Brochure Page 1 and Page 2

Flo-et Flow Control Brochure

Res-Kem Resin Trap Information

3D CAD Drawings for Condensate Polishers for University in Massachusetts

noreply@blogger.com (T Dupnik) — Tue, 15 Nov 2011 21:23:00 +0000

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.

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.

Alternate view of 3D CAD drawing of Stainless Steel Condensate Polishers

Water Sampling a Critical Step in Residential Water Equipment Selection

noreply@blogger.com (michael urbans) — Fri, 28 Oct 2011 18:56:00 +0000

For our wholesale equipment customers who treat well water, we offer a very basic water analysis. Ultimately, the success of the water treatment starts with proper sampling methods. We aren't talking rocket surgery here. Most residential water treatment systems can be prescribed by testing for 3-5 parameters, including hardness, pH, iron and Total Dissolved solids (TDS). However, what I find are samples collected in old pickle jars with little documentation. Most treatment companies will provide you with a clean sample bottle and a questionnaire, not pickle jar the home owner gave you. If your customer wants an independent analysis, your customer can also find a certified laboratory in your State.

Critical questions for a questionnaire:

Is there an existing treatment system?
How powerful is the water pump?
How many bathrooms?
Any mega showers and Jacuzzi tubs? Irrigation?
Taste, odor, color?

Make as many observations as possible, listen to the homeowner. Part of your sample tool kit are your eyes, ears and nose. One of the best water observation tools are is a simple white Styrofoam cup. Fill it with water and see if there is any color or sediment. Always carry a washing machine hose and 5 gallon bucket. They make great sampling tools, especially if you are sampling from the well tank. Run off at least one five gallon bucket to clear the line.

LaMotte Color Q DW model 2059

Of course you can forgo future brow beating and lectures from me if you purchase your own test kit and test the water yourself. You'll still need to ask the same questions above. Test kits range from mild to wild. We use the LaMotte Color Q DW model 2059. Now don't get excited. We don't sell test kits we sell the equipment after the test. If you get it right, every one's happy.

For additional information:
Certified water testing laboratories in your State
LaMotte Drinking Water Testing Products

Condensate Polishing System Shipped to University in Massachusetts

noreply@blogger.com (T Dupnik) — Fri, 28 Oct 2011 18:03:00 +0000

A triple all stainless steel condensate polisher was shipped to a university in Cambridge, Massachusetts. The system is designed to treat 445 gpm of condensate and is replacing an existing unit which had reached the end of its life. This is part of a major upgrade of the steam plant including the condensate polishers, a triple dealkalizer system, which Res-Kem will provide in November, and a deaerator.

Res-Kem Triple Stainless Steel Condensate Polishing System

Here are the key features of the condensate polisher:

For long equipment life, the system has three, 54" ASME-code tanks manufactured in 304 L stainless steel.
To simplify field installation, the system includes inlet, outlet, drain, backwash supply, brine and sub-surface wash headers.
The condensate polisher incorporates Bray 31 series butterfly valves with 92 series air open/air close actuators.
We supplied a custom designed FRP NEMA 12 panel with an Allen Bradley PLC with three solenoid boxes..
304L stainless steel face piping.
Regeneration initiated via totalized flow or differential pressure.
The flow sensors to measure the treated condensate from each of the vessels were supplied by others.
The differential pressure switches are Orange Research 1203 DP transmitters with 4-20 mA output.
A subsurface wash is included to increase the time between regenerations increasing total energy efficiency.
A brine distributor for reduced salt usage
A separate source backwash is included to increase condensate heat recovery.
To prevent downstream damage, stainless steel resin traps are included in the treated water line.

Condensate Polishing System Being Off-Loaded at Customer's Site

Given the small space where the system is located, the standard design of the condensate polisher had to be re-engineered. For example:

The three pressure vessels could not be evenly placed because a vertical support beam would be in the way making each header piece unique.
A height restriction required numerous engineering design iterations to get the system in the space allotted.
All headers needed to be nested in a very small envelop on the front of the system.

Additional information:

Condensate Polisher Checklist Webpage Version
Condensate Polisher Checklist - PDF Version
Condensate Polisher System Brochure
Need Applications Engineer