500 Point Breeze Rd. Flemington, NJ 08822 (908) 782-5800 Phone (908) 782-3380 FAX www.zrpure.com Isolux Arsenic Removal Systems Central Treatment Systems Operation and Maintenance Manual - 1
Contents 1. System Description 3 2. Safety Considerations 6 3. System Installation. 7 4. System Start-Up.. 8 5. System Operation and Maintenance Arsenic Monitoring 9 System Operation and Maintenance... 9 Pre-Filter and Isolux Cartridge Replacement 9 Pre-Filter Service. 9 Isolux Housing Service. 10 Storage and Handling Of Isolux Cartridges 11-2
1. System Description Existing Chlorination Point Well Supply Header Existing Sample Existing Sample Valve No. 1 Valve No. 2 Valve No. 1 Electrical Supply (460 v/3 phase/60 Hz) By-Pass Valve Flow Totalizer Isolux Module Sample Valve No. 3 To Existing Distribution System Return Header Check Valve Valve No. 3 Sample Valve No. 4 Figure I. Typical Treatment Flow Diagram The system consists of the following components: Module No. 1 Complete 80 gpm Treatment System Comprising: A. Two 48 X 20 Coated Steel Tanks 100 psi pressure rated B. 1-1µ Stainless Steel Particulate Pre-Filter Housing C. 1-1µ Bag-Type Particulate Pre-Filter D. 1-3 hp Booster Pump, 480 v, 3-Phase E. 18 42 Isolux Arsenic Removal Cartridges - 3
The system has two coated steel tanks, or housings. The two housings combined contain 18 (eighteen) Isolux cartridges. The combined system is rated for maximum operation at 80 gpm with the two housings in parallel. The pressure drop across the system has been tested to be approximately 30 psi at 80 gpm. The following details the system specifications: Contaminant Removal Max. Flow Rate ISOLUX CTS Specifications Arsenic III & V 80 gpm # of Vessels 2 # of Cartridges 18 replaceable Isolux MC (9 per vessel) Media Bed Residence Time 27 seconds Typical Media Life* Up to 1,000,000 gal ph Range Booster Pump Flow Regulator Pre-Filter Cartridge Disposal 7 8.5 ph Included Included 1-micron Bag Type Included Landfill or return to MEL ISOLUX CTS Technical Specifications System Footprint: 48 W x 48 L x 60 H Vessel Size: 20 OD x 48 H Number of Vessels 2 Vessel Description 200 psi (customizable) rated carbon steel with NSF grade epoxy coating Cartridge Size 4.5 OD x 42 L Cartridge Dry Weight Shipping Weight (dry) Operating Weight External Piping Outlet Connection Inlet Connection 22 lbs 1500 lbs 3200 lbs 2 Sch. 80 PVC, glued 2 PVS Slip 1 ¼ NPT Electrical Requirements 3 hp, 230/460 v, 3ph - 4
The system utilizes a manual flow control valve to tune the booster pump to the requirements of the site. The flow diagram shows the interconnecting piping between the well, the Isolux system, and the storage tank. The system uses a 3 hp booster pump which requires 208-230/460 v 3-phase power. The booster pump must be tied-in to the well pump so that it comes on and off with the pump. Use of a time delay relay is recommended so that there is a 10 second time delay between start-up of the well pump and start-up of the booster pumps. No time delay on shutdown is necessary. A Material Safety Data Sheet for Isolux media is included as an attachment. Further information on the pre-filter is included as an attachment. Further information on the booster pump is included as an attachment. - 5
2. Safety and Handling Considerations Isolux media is NSF Std. 61 certified and is non-hazardous. A Material Safety Data Sheet is included with this manual as Attachment I. Install this system on cold water only. Do not use on water lines exceeding 100 F. Maximum water pressure for this system is 100 psi. Protect the system from direct sunlight and from temperatures below 35 F. Use only NSF approved pipe dope or similar compounds on plastic pipe. Glue all joints or use Teflon tape to seal pipe thread joints. Keep exterior surfaces of the system clean with soap and water. Do not use spray cleaners or insecticides near this system. Always wear safety glasses during installation. Spent Isolux cartridges are non-hazardous and should always be disposed of properly. Isolux media and cartridges should not be exposed to air for a prolonged period before installation. Prolonged exposure to air will have a negative effect on the media or cartridge s capacity to adsorb arsenic. Isolux cartridges should remain sealed in their air-tight wrappers until just prior to installation. No work should be done on any element of the system without first shutting that element down and releasing any pressure. Lockout/Tagout procedures consistent with OSHA requirements must be employed. The pre-filter and cartridge housings are designed for a rated pressure. Operating pressure in excess of the pressure rating creates a serious safety hazard. The pre-filter and cartridge vessels are provided with pressure gages. These pressure gages must be operational at all times when the system is functioning. The pre-filter and cartridge housings are equipped with vents so that residual pressure can be vented when they are taken out of service. Never attempt to open the pre-filter or cartridge housing without first opening the vent to relieve residual pressure. - 6
3. System Installation Upon arrival, carefully unpack all equipment and check for damage. Remove any enclosed Operations & Maintenance Manual, data sheets, or MSDS s. Pressure gauges to be installed on the lid of each cartridge vessel have been wrapped in plastic and placed on the equipment skid. Two top tubesheets and two pre-filter bags have been packaged with the cartridge skid. Take care not to switch inlet and outlet connections during installation. Inlet and outlet connections are identified on the drawing. All interconnecting piping is Sch. 80 glued PVC, either 2 or 3 as shown in the flow diagram. Any new valves used in the installation should be one-quarter turn ball valves. As shown on the flow diagram, installation with a by-pass line around the arsenic removal system is recommended as it simplifies system startup. All valves and piping supplied on individual modules are 2-inch Sch. 80 PVC. All materials in contact with water are NSF certified or FDA compliant. Electrical supply to the booster pump must be tied into the well pump so that when the well pump starts or stops the booster pump also automatically starts or stops. Use of a time delay relay is recommended so that there is a 10 second time delay between start-up of the well pump and start-up of the booster pump. No time delay on shutdown is necessary. - 7
4. System Startup Initial start-up instructions assume that the well is in operation supplying the storage tank via a by-pass line, that all manual valves are closed, and that the booster pump is electrically connected but with the disconnect in the off position. Prior to initial start-up, open all housings and install the pre-filter bag and all Isolux cartridges. Do not remove the Isolux cartridges from their protective, clear plastic bags until you are ready to install them in the cartridge housings. For detailed instructions on cartridge replacement see Section 5(C). For initial start-up with a new set of cartridges: 1. Make sure the pre-filter housing and the cartridge housings are securely closed. Open the vent on the top of each of the three housings. Open the flow control valve to its maximum setting. Connect a hose to the Sample Valve No. 3 so it can drain outside of the well house. Make sure the manual inlet and outlet valves to each cartridge housing are open. 2. Slowly crack open Valve No. 1 and allow the pre-filter and cartridge housings to fill until water emerges from the vent at the top of each. Once water emerges, close the vent. 3. Open Valve No. 1 completely. Slowly open Sample Valve No. 3 and allow water to flush to the drain. Exercise caution because the initial water from the sample valve may be hot. Water temperature should return to ambient within one minute. This is a normal result of the initial activation of the media. 4. Flush approximately 405 gallons to the drain. This is equivalent to 10 bed volumes. After flushing, close Sample Valve No. 3 and open the product water shutoff valve No. 3. 5. Slowly close the valve in the by-pass line in order to force the output of the well pump through both modules. When the by-pass line is fully closed, turn on the booster pump. 6. Adjust the flow control valve with the booster pump in operation so that the flowrate through the system matches the well pump output. 7. The system is now on-line. - 8
5. System Operation and Maintenance A. Arsenic Monitoring 1. Product water arsenic level should be checked within several hours of system start-up at the Sample Valve. Use a field test kit or sample bottle supplied by the laboratory that will do the analysis. Follow the laboratory or field test kit instructions. The arsenic level measured either way should be non-detectable. If any measurable arsenic result is obtained, contact Isolux immediately. 2. When taking samples for arsenic measurement, always run the sample port for several seconds before taking the sample. 3. Arsenic measurement in the product water should be performed at some frequency to be determined by regulatory requirements. Follow the field test kit or laboratory instructions. When the product arsenic level equals 80% of the applicable MCL, it is time to replace Isolux cartridges. B. System Operation During normal operation, the Isolux Arsenic Removal System requires no operator actions other than periodic measurement of the product water arsenic content. C. Pre-Filter and Isolux Cartridge Replacement Exercise caution when opening the pre-filter housing or any Isolux housing as they may be under pressure. Be sure to close both the inlet and outlet valves prior to opening any housing. If the housing is equipped with an air bleed valve at the top, open it to vent any pressure before opening the housing. Pre-filters should be changed each time Isolux cartridges are replaced. When sufficient operating experience has been accumulated, the Purchaser may decide to change prefilters on a different schedule. When servicing the Isolux system, first shutdown the booster pump and the well pump, and close the inlet and outlet shutoff valves. - 9
D. Pre-Filter Service: Make sure valves No. 1 and No. 3 are closed. Make sure both the well pump and the booster pump are not in operation. Remove the bolts or other devices that secure the top of the pre-filter housing and remove the top, setting it to one side. Remove any internal pieces so that the top of the bag is exposed. Remove the used bag and properly dispose of it. Install a new bag and any internal pieces holding it in place. Re-install the top and tighten the bolts or other devices that secure it in place. More detailed instructions can be found in the information from the filter manufacturer. E. Isolux Housing Service: For a two-housing system, cartridges in both housings will typically be changed at the same time. Therefore a total of 18 cartridges will be removed and replaced. Start with one housing and service it completely before starting to service the other housing. When servicing, make sure valves No. 1 and No. 3 are closed. 1. Connect a hose to the Sample Valve No. 3. Open the sample valve and the vents on the top of each housing and allow the water in the housing to drain out. 2. Remove the bolts or other devices that secure the top of the two housings and lift the top. The top is spring loaded so that it lifts easily and will remain in a vertical position while servicing is underway. Lift out the top tubesheet so that the tops of the individual cartridges are exposed. 3. Lift the spent cartridges out of the first housing. Allow any free water from the cartridges to drain back into the housing as they are removed. Remove all spent cartridges before installing any new ones. Allow the spent cartridges to stand off to one side while new cartridges are installed. This gives time for most of the free water to drain. Spent cartridges should be placed in plastic bags and disposed of properly. 4. Insert new cartridges taking care that they properly seat at the bottom of the housing. One end of each cartridge has an opening in the center. This end goes in the bottom of the housing. Lubricate this opening with any NSF certified lubricant prior to installation. The opening in each cartridge mates with a pipe nipple in the bottom tubesheet equipped with dual o-rings. The dual o-rings seat inside the cartridge opening, and the cartridge itself sits on the bottom tubesheet. - 10
5. Install nine cartridges in the first housing. The end of each cartridge that is now at the top of the housing has a plastic nub that projects from the center of the cartridge end. Each of these plastic nubs mates with a hole in the top tubesheet. Re-install the top tubesheet so that each of the nine cartridges is held in position by the tubesheet. 6. Close the housing lid carefully and re-secure it. Four flexible balls attached to the top tubesheet make contact with the underside of the lid and this holds the housing internals in place. 7. Repeat this procedure for the second housing. When work on both housing has been completed, see Section 4 for startup procedures. F. Storage and Handling of Isolux Cartridges Isolux cartridges contain Isolux s patented zirconium hydroxide media for adsorption of arsenic. The media is a relatively fine powder with a structure that can be affected by handling and vibration. Improper handling or excessive vibration can reduce the service lifetime of the cartridges. Follow these guidelines when handling cartridges. Isolux cartridges should always be transported and stored in an upright position. The cartridge shipping container is designed for storage. Cartridges should not be removed from the shipping container until they are ready to be installed. Keep cartridges in a cool, dry location. Protect cartridges from rain and from freezing weather. Avoid excessive vibration. Cartridges should not be stored in a truck or other vehicle in over-the-road service. - 11