Customized Greensand Filter for Brewery Prepared for Shipping

With factory testing completed, Res-Kem's greensand filter with several advanced features is ready for shipment to a local brewery.  Because the water is integral to production of their beer, this expanding brewery needed features which are not typical for a greensand filter:

• Allen Bradley CompactLogix PLC with Ethernet gateway to communicate with the central plant control system.
• Expandable, in the field, from four to eight parallel greensand filter units without requiring reprogramming of the PLC.
• Multiple, user definable,  regeneration initiation options including manually initiated, differential pressure and/or totalized flow.
• Valve position feedback to insure when a valve supposed to be open or closed, the valve is in the correct position.  If incorrect, an alarm will sound and be indicated on the Panelview 1000 HMI.

Quad 48"Diameter Greensand Filter During Factory Testing

General System Information:
Four tank, continuous regeneration non-skid mounted greensand system with manual, differential pressure and/or totalized flow initiated regeneration. The system is constructed of four, 48" diameter fiberglass, non-ASME code, rated at 100 psig working pressure tanks. The system is controlled using an Allen Bradley CompactLogix PLC with an Allen Bradley Panelview Plus 1000 touchscreen HMI.  The system has Georg Fischer pneumatically actuated air-to-spring ball valves with visual and electrical valve indication.  The face piping is Schedule 80 PVC pipe and fittings.  Each vessel contains 38 cubic feet of Greensand Plus for high iron removal.  To allow for iron removal, the incoming water will be treated continuously with a chlorine dioxide generator.

Touchscreen Panelview Plus 1000 HMI for Equipment Control

For Additional Information:

Greensand filter brochure

To determine if a greensand filter will work for your company, contact us.

Water Softener Shipped to Luxury Hotel in Delaware

Water softener for a new luxury hotel in Wilmington, Delaware was shipped from our Res-Kem Aston facility.  This system treats all the incoming Wilmington city water for the entire hotel including bathrooms, restaurant, etc.  With the special piping configuration, dual flowmeters and special Pentair NXT controller, the system operates in alternating, parallel or demand modes with simple programming changes.
 

150 gpm Continuous Water Softener System with
Carbon Steel Face Piping and Interconnecting Headers

Enduser	Water softener for a new luxury hotel in Wilmington, Delaware to treat all the incoming water for the entire building sold to through a local engineering firm
General water treatment application	Two large 48”X60” water softeners for removal of water hardness and iron.
Operating conditions	150 gpm continuous operation
System configuration	Dual ASME-Code 48” X 60” alternating softener tanks each with a separate Seametrics flowmeter 40 cu ft of 8% crosslinked softener resin per vessel 50” X 60” polypropylene brine tank
Materials of construction	Skid mounted Internally and externally epoxy coated, carbon steel pressure vessels Schedule 40 welded /flanged face piping
Type of valves and actuators	Cast iron, Series 42 Pentair Aquamatic diaphragm valves
System Control	Each softener has an Pentair Aquamatic NXT stager/controller Special piping, dual flowmeters and special controller allows for alternating, parallel or demand operation with simple programming changes
Special Features	System was skid mounted to allow for lifting of unit to the top floor of the building during construction

Additional Information:

Industrial water softener brochure

Commercial water softener brochure

Dual Tank Commercial water softener brochure

I need help sizing a water softener

Condensate Polisher Shipped to New Jersey University

Last week, Res-Kem shipped a condensate polisher to a New Jersey university.  This condensate polisher will be installed as part of a new onsite power production facility at the university operated by an independent energy development company.  They will produce power for the university under a DBOM (Design, Build, Operate, Maintain) agreement. Excess power produced gets sold to the PJM.

Dual, Skid Mounted Stainless Steel Condensate Polisher with Headers

Customer	An independent energy development company specializing in the development, engineering, construction, start up, commissioning, operation, maintenance and management, as well as, ownership of Central Energy Centers, Renewable Energy projects and Combined Heat, Chilling and Power  Production Facilities.
General water treatment application	Two large 48”X60” sodium cycle condensate polisher for removal of contaminants in the return condensate and the return condensate from the steam driven chillers on-site
Savings and/or ROI the customer wants to achieve	Fuel and chemical saving related to the removal of iron and calcium from the condensate streams and ultimately the boiler feedwater
Operating conditions	250 gpm max, 150 gpm continuous operating at 180F
System configuration	Twin parallel / Alternating system
Materials of construction	Skid mounted 304 SS pressure vessels Schedule 10 welded /flanged face piping
Type of valves and actuators	Bray valves with Bray actuators
System Control	Allen Bradley PLC operates the system as alternating or parallel
System schematic	Polisher collectively handles two condensate streams – return condensate from campus and condensate from steam driven chillers
Special Features	Sample cooler mounted on skid which can sample the inlet and outlet of each vessel Inlet and outlet headers between each system on skid

Additional Information:
Listing of Condensate Polishers Built by Res-Kem
Online Catalog of Res-Kem Condensate Polishing Equipment
Condensate Polisher Technical Bulletin
Condensate Polisher Application Checklist 
For Technical Help From a Res-Kem Sales and Application Engineer

Second Condensate Polishing System Shipping to a North Carolina University

Res-Kem is shipping the second of two condensate polishing systems to a leading private university in North Carolina next week.  This is the second of two systems sold to this same university in the past year and a half.  This system treats 400 gpm of dirty condensate.

Res-Kem's Dual 54 inch Sodium Cycle Cycle Condensate Polishers

To improve the ROI, through energy savings, this system is designed with a separate source of cold water for backwash, brine draw and slow rinse.

What is the Res-Kem water treatment application?	Sodium cycle condensate polishing to remove iron and hardness
What are the operating conditions?	Flow: 400 gpm Pressure: 30-100 psi Temperature: 200F Continuous
What is the system configuration?	Dual tank, parallel operation 54” in diameter tanks
What ion exchange resin was used?	47 cubic feet of Purolite C-150 highly cross-linked macroporous cation exchange resin in each tank
Materials of construction?	316 SS ASME code with a 150 psig design pressure 316 SS Hub and Lateral 316 SS Subsurface Wash Distributor 316 SS Schedule 40 Welded face piping
Type of Valves and Actuators?	Bray McCannalok Series 41 with Series 93 pneumatic actuators with manual override
Special Features?	Subsurface wash Cold water used for separate source backwash, brine draw and slow rinse Condensate fast rinse 316 Stainless resin traps after each system

Additional Information:
Listing of Condensate Polishers Built by Res-Kem
Online Catalog of Res-Kem Condensate Polishing Equipment
Condensate Polisher Technical Bulletin
Condensate Polisher Application Checklist 
Purolite C-150 Technical Bulletin
For Technical Help From a Res-Kem Sales and Application Engineer

Growing DI Exchange Business Means Additional DI Tanks Needed

As the number of customers continues to increase for our deionized water exchange service, Res-Kem General Water continues to heavily invest in new DI (deionization) tanks and mixed bed ion exchange resin.  We just received our first of three shipments of our all stainless steel DI12 and DI30 tanks.  Res-Kem continues to have the largest fleet of stainless steel deionization exchange tanks on the East Coast.  

All Stainless Steel Service DI Tanks Received at Res-Kem for Growing DI Exchange Business

These exchange tanks and resin are used to produce high purity to ultrapure water for many industries including power, cogeneration, beverages, electronics, semiconductors, universities, corporate research campuses, pharmaceuticals, and manufacturers of most any type where high purity water is used in the product or touches the product.

Locations Served:
Res-Kem will use these primarily for customers in our southern region which includes New York, New Jersey, Pennsylvania, Delaware, Maryland, DC, Virginia and North Carolina out of our Aston, PA and Colonial Heights, VA locations.

Also, we have a large fleet of DI tanks serving our northern region New York, Connecticut, Massachusetts, Rhode Island, New Hampshire, Vermont, and Maine out of our New Britain, CT and Avon, MA locations.

For More Information:On Res-Kem General Water's DI Exchange Service
Technical and/or sales questions

DI System Shipping to Washington Chemical Plant

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.

Condensate Polisher Product Bulletin Updated

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

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?

New Two Bed Demineralizer Technical Bulletins

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.

Condensate Polisher Ready for Shipment to Chemical Plant in Louisiana



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:

• Contact a Res-Kem condensate polisher expert.
• CP Product Bulletin
• Condensate Polisher Checklist PDF
• CP Checklist Webpage
• Value Engineering White Paper

Condensate Polisher Shipped to Arkansas

We shipped another condensate polishing system last month. This dual tank unit was shipped to a government facility in Arkansas.

Here are the key features of the polisher:

• The system has two, 36" stainless steel, ASME-code tanks mounted on a skid to treat steam condensate.
• The condensate polisher incorporates Bray 31 series butterfly valves with 93 series air open/spring return actuators.
• We use a custom designed FRP NEMA 4X panel with an Allen Bradley PLC.
• 304L stainless steel face piping.
• Regeneration initiated via totalized flow or differential pressure.
• Seametrics model IP101S flow sensors measure the treated condensate from each of the vessels.
• The differential pressure switches are Orange Research 1201 series.
• A subsurface wash is included to increase the time between regenerations increasing total energy efficiency.
• A separate source backwash is included to increase condensate heat recovery.

Additional information:
Condensate Polisher system brochure
Condensate Polisher Checklist
Need Applications Engineer

Condensate Polisher Shipped to a Virginia University

This past month, we have built and sent another condensate polisher to a major university in Virginia. This stainless steel system with carbon steel piping is designed to treat 175 gpm and designed to operate at 100 psig and 200 F. The system has dual ASME-code 36 inch diameter tanks. The piping is Schedule 80 carbon steel with flanged connections.
The system has stainless steel ion exchange resin traps on each vessel to protect equipment downstream from catastrophic underdrain damage.

The valves used where Bray butterfly valves with air actuators and handwheel overrides. The system used AquaMatic Controllers.

Industrial Water Softener Skid-Mounted Shipped

I try to keep up with our shipments, but with all the systems going out recently, I missed posting this dual tank industrial water softener out about two weeks ago.
The system is a dual tank alternating, skid mounted, water softener, including interconnecting piping and isolation valves. GE Aquamatic composite diaphragm valves are used for system automation. A GE Aquamatic 962 series controller opens and closes the Aquamatic valves during regeneration. The tanks are epoxy lined carbon steel with an epoxy exterior and 100 psi ASME code. Face piping consists of Schedule 80 PVC pipe and fittings. Regeneration initiated by either gallon throughput or timeclock.

Custom Manual Water Softeners Shipped

Last week, we shipped two custom water softeners. The customer was using the softeners to treat the water feeding plant safety showers. Res-Kem has the flexibility to take our standard industrial water softener designs and modify them to meet a specific customer's requirements for virtually the same cost as our standard systems.

For example:
The plant has strict explosion-proof requirements. Even with the multitude of standard designs Res-Kem has using Fleck, Autotrol, Aquamatic, and Bray valves and Aquamatic electro-mechanical or Allen Bradley controls, we collectively determined the cost to accomplish an automatic, explosion-proof design was too great for the application.

So, each system is a single tank unit with manual regeneration. The face piping was Schedule 80 PVC. The valves were true union ball valves. Polyethylene lined composite fiberglass tanks with laminate glass exterior, 150 psi ASME code. Also, the customer requested a pressure relief valve for over pressure protection.