.

Keywords: EPRI NP 7383

E I
Electric Power
PWR
Water quality
Project S30713
Final Report
>
Water chemistry September 1991
Research Instituto Nuclear steam generators

I
.- :

|
| o

' ??9[ L Design and Operating Guidelines

Wld b for Condensate Polishers in
Nuclear Power Plants .

|
!
|
|
*
|

x
j
1
.

'

i
i Prepared by
| GEBCO Engineering, Inc. !
l
Sebastopol, California 1
|
and
NWT Corporation
San Jose, Califo nia

9110290077 911009 '

PDR TOPRP EXIEPRI

b PDR
. . . _ _ _ _ _ _ __ . _ - _
 -. _ .- - - .-.

,____

REPORT SUMMARY

Design and Operating Guidelines for Condensate

Polishersin Nuclear Power Plants
- - Control of i npurity ingress to P7/R steam generators is essential to
prevent significant corrosion damage. A properly designed and oper-
ated condensate polisher system can significantly reduca the quardity
*
of impurities transpotted to steam generators and can provide a mea-
sure of protection in the event of a condenser leak.

BACKGROUND PWR steam generator corrosion has resultod in high costs and
reduced plant availability. Several studies have shown that a properly designed
INTEREST CATEGORIES
-
and maintaincd condensate polisher system can significantly reduce the transport
of corrosion products and ionic!mpurities, in addition, concensate polishers pro-
- Nuclear plant corros. ion vion, protection of the steam generator during limited periods of condenser cooling-
control water leakage.
Steam generator reliability
OBJECTIVE To provide recommendations for the design and operation of con-
KEYWORDS densate polishing systems, with the overall objective of controlling corrosion prod-
_,,,,,, _

. uct and impurity ingress to the steam generator.

Water quality
Water chemistry
APPROACH The project team gathered operating and maintenance data through
man surveys, personal visits, and related project reports. They ootained industry
- Nuclear steam generators
review and comments and organized the information m the form of guidelines.
.

RESULTS Recommenoations and associated justifications are provided for the

design and routine operation of both deep-bed and powdered-resin systems.
Specific areas addressed incluoe the following:
. Distribution and underdrains systems
*
. Instrumentation and sanipling lines
. Piping ,

. . Regeneration systems
. Fines filters
. Flow rates and distribution
. Precoat mixing systems
. Operator training
. Maintenance
. Flow balancing
. Regeneration and transfer procedures

EPRI NP-7383s Electric Power Research institute

 ... _
m. _

%'91 PERSPECTIVE These guidelines will assist utilities in designing

cundensate polishing systems for now plants or adding systems as major
backfits. Operating guidelines are provided to ensure optimum system
performance Condensate polisher design and operation is continually
improving, with new information disseminated through periodic EPRI-
sponsored workshops. To request copies of these proceedings, contact
EPRI project manager Tom Passell,(415) 855 2070. The next EPRI con-
densate polisher workshop is planned for September 10-12,1991, in -
Valley Forge, Pennsylvania,

PROJECT
RPS30713
Project Manager: C. S. Welty, Jr.
*
Nuclear Power Division
Contractors: GEBCO Engineering, Inc.; NWT Corporation
*
For further infortnation on EPRI research programs, call
EPRI Technical Information Specialists (415) 855-2411.

b -

8
9

'a
_ _ _ _ _ _ _ _ - -
 . - . . ._ ._ _ _

Design and Operating Guidelines i

for Condensate Polishers in
Nuclear Power Plants
NP-7383
Research Project S30713

Final Report, Septemt:er 1991

n

'4

Prepared by
GEBCO ENGINEERING, INC.
138 North Main Street, SJite 36
Sebastopol, California 95472

NWT CORPORATION
7015 Reatrn Drivc
San Jose, California 95119

DISCLAIMER OF WARRANTIES AND

LIMITATION OF LIABILITIES-
THIS REPORT WAS PREPARED BY THE ORGANIZATION (S) NAMED BELOW AS AN
ACCOUNT OF WORK SPONSORED OR COSPONSORED BY THE ELECTRIC POWER
RESEARCH INSTITUTE. INC. (EPRI). NEITHER EPRI. ANY MEMBER OF EPRI, ANY
COSPONSOR. THE ORGANIZATION (S) NAMED BELOW, NOR ANY PERSON ACTING
ON BEHALF OF ANY OF THEM:
(A) MAKES ANY WARRANTY OR REPREbENTAT!ON WHATS0EVER, EXPRESS OR
^- - IMPLIED, (1) WITH RESPECT TO THE USE OF ANY INFORMATION, APPARATUS,
METHOD, PROCESS, OR SR.;lLAR ITEM OISCLOSED IN THIS REPORT. INCLUDING
MERCHAP'TABILITY AND FITNESS FOR A PARTICULAR PL'RPOSE, OR (11) THAT SIICH
.USE DOES NOT INFRINGE ON OR INTERFERE WITH PRIVATELY OWNED RIGHTS.
.- INCLUDING ANY PARTY'S INTELLECTUAL PROPERTY. OR (Ill) THAT THIS REPORT
- IS SU!,ABLE TO ANY PARTICULAS USER'S CIRCUMSTANCE; OR

(B) ASSUMES RESPONSIBILITY FOR ANY DAMAGES OR OTHER LIABILITY

WHNS0EVER (INCLUDING ANY CONSEQUENTIAL DAMAGES. EVEN IF EPRI OR ANY
EPRI REPRESENTMIVE HAS BEEN ANISED OF ThE POSSIBILITY OF SUCH DAMAGES)
RESULTING FROM YOUR SELECT 10N OR USE OF THIS REPORT OR ANY INFORMADON.
Prepared for
APPARATUS. METH00. PROCESS, OR SIMILAR ITEM DISCLOSED IN THIS REPORT Electric Power Reeearch instltute
3412 Hillview Avenue
ORGANIZATION (S) THAT PREPARED THIS REPORT: Palo Alto, California 94304
GEBCO ENGINEERING, INC.
NWT CORPORATION
EPRI Project Manager
C. S. Welty, Jr.

Steam Generator Reliability Program

Printed on Recycled Paper Nuclear Power Division

._ ___ __ ____
 9
-
,

*
i

1
1

-- EWetnc Pm Research Institute and EPHP are registered serwce marus of Electnc Power Reseaech trvature,. Irc

Copfignt 01991 Electre Power Researctiinstituta inc All nghts resen, tut
,

ORDERING INFORMATION -
Roquests for copies of this report should be directed to Research Reports Center
(RRC). Box 50490,. Pa!o Alto, CA 94303. (415) 965-4081, There is no charge for reports
requested by EPRI member uti' ties and affihates. U S utikty associations, U.S. government
agencies (fork,ral; stato, and local), rnedia. and foreign organizations with which EPRI has
an inform ;tiu exchange agreement. On request - RRC will send a catalog of EPRI reports.

_
 ?

__

AUSTRACT

Recommendations and associated technical justifications are provided for the

design and operation of condensate polishing systems. Both deep bed and
powdered resin systems are addressed.

The objective of the guidelines is to ensure that impurity levels ~ in the PWR
secondary cycle are reduced to the minimum achievable levels through
~
proper design and operation of the condensate polisher system. Reduction of
the condensate polisher to the steam generators has been demonstrated to
improve steam generator reliability and limit corrosion of steam generator
,
materials.

(
|.
!

,
-.

l
3.
i.

iii

.. - .- - . - .-.
 ,

.|
|

ACKNOWLEDGEMENTS :

This guideline document is a rewrite of " Condensate Polisher Design,

Operation, and Maintenance Guidelines", Rev. O, originally written by NWT
Corporation, with little change in technical content.
4

'
S

'

l-

..

'
L.

|
j ..

... - - - .
 _ _

i
i

TABLE OF CONTENTS

: Section IMge |

1.0- INTRODUCTION 1-1

2.0 SCOPE AND APPLICABILITY 2-1

.

3.0 DEFINITIONS 3-1

'
4.0 DESIGN CRITERIA: DEEP BED POLISHER SYSTEMS 4-1

Rl! COMMENDATIONS:

4.1 SERVICE VESSELS 4-1

4.1.1 Influent Water Distribution 4-1
4.1.2 .Underdrain Design 4-1
4.13- Sight Glasses- 4-3-
.4.1.4 Recirculation System 4-3
^
~4.2 C ATION REGENERATION AND SEPARATION VESSELS 4-5
4.2.1 Underdrain for Cation and Separation Vessels 4-5
4.2.2 Cation Vessel Influent Water Distribution 4-5
4.2.3 Sampling Penetration 4-5
4.2.4 - Distribution of Acid 4-6
4.2.5 Cation Resin Takeoff 4-6
4.2.6 --Sight Glasses in Cation Vessel 4-6
-4.3 ANION VESSEL 4-7-
4.3.1 Underdrain of Anion Vessel 4-7
a 4.3.2- Rinse Water Distribution 4-7-
4.33- Resin Addition / Removal Penetration 4-7
. 4.3.4 -Caustic Distributor Laterals 4-7
4.3.5 - Anion -Resin Take-off 4-8
4.3.6 Sight Glasses in Anion Vessel 4-8
4.4 ~ MIX.AND STORAGE VESSEL '4-8
4.4.1~ Storage Vessel Underdrain - 4-8
4.4.2 ; Storage Vessel Resin Take-off 4-8
4.4.3 Storage Vessel Sight Glasses 4-9

vil
 . _ . . ._ _ _ .

TABLE OF CONTENTS (continued)

,

Section Page

4.5 REGENERANT CHEMICAL SYSTEit 4-9

4.5.1 System Materials of Construction 4-9
4.5.2 Regenerant Metering Pumps 4-9 ,

4.6 PIPING, VALVES, AND RESIN TRAPS 4-10

4.6.1 Piping Materials of Construction 4-10
'

4.6.2 System Layout 4-10

4.63- Resin Trap Design 4-10
4.6.4 Resin Fines Filters 4-10 ,

4.7 INSTRUMENTATION 4-13

4.7.1 Operational Process Instrumentation 4-13
'
-4.7.2 Regeneration Process Instrumentation 4-20

5.0 - DESIGN CRITERIA: POWDERED RESIN SYSTEMS 5-1

RECOMMENDATIONS:

- 5.1 POLISHER VESSEL 5-1

5.1.1 Inlet Flow Distributors 5-1
5.1.2 Septum Design 5-1
5.1.3 Air and Water Supply 5-1
5.1.4 Sight Glasses 5-2
5.2 PRECOAT SYSTEM 5-2
5.2.1 Precoat Mixing System 5-2
,

5.2.2 Precoat Pump 5-2 ,

5.2.3 Holding Pumps 5-2

5.2.4 Resin Strainers 5-3
^
5.2.5 Resin Fines Filters 5-3
5.3 INSTRUMENTATION 5-3
5.3.1 Precoat System Process Instrumentation 5-3

viii
_ _ - _ _ _ _ _ _ _ - _ _ - . . .

_ _ _ _ ,

TABLE OF CONTENTS (continued)

Section Page

6.0 OPERATING AND MANAGEMENT CONSIDERATIONS 6-1

RECOMMENDATIONS:

,
6.1 MANAGEMENT OF CONDENSATE POLISHERS 6-1
6.1.1 Management Support 6-1

,
6.1.2 Commitment to Resources 6-1
6.1.3 Maintenance Program 6-1

7.0 OPERATING CRITERIA: DEEP BED POLISIIER SYSTEMS 7-1

RECOMMENDATIONS:

7.1 Termination of Service Run 7-1

7.2 Balancing of Flow 7-2
7.3 Hold Point in Regeneration Process 7-2
7A Air Scrubbing 7-3 -

7.5 Backwash and Settling 7-4

7.6 Anion Resin Transfer 7-6
7.7 Concentration of Regenerants 7-7
7.8 Quality of Regenerants 7-7
~

7.9 Rinsing 7-10

7.10 Second Air Scrub Technique 7-10
7.11 Mixed Resin Rinse 7-12
7.12 Visual Inspection 7-12
-
7.13 Resin Mixing 7-12
7.14 Final Rinse 7-13
. 7.15 Resin Transfer 7-13

ix

- - _ - _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ .
 I

TABLE OF CONTENTS (continued)

Eection M

8.0 OPERATING CRITERIA: POWDERED RESIN

-POLISHER SYSTEM 8-1

RECOMMENDATIONS:
.

8.1 Maximum Pressure Drop 8-1

8.2 Balancing Flow Rate- 8-2
8.3 Backwash Flow Rates 8-2
8.4 Resin Loading 8-2
8.5 Preparation of Resin Slurry 8-2
8.6 Flow During Precoat Process 8-3
8.7 Minimum Time in Hold Mode 8-4
8.8 Use of Body-Feed for Additional Capacity 8-4

9.0 REFERENCES 9-1

10.0 CHECKLIST 10-1

APPENDIX A: DISCUSSION OF DISTRIDUTORS A-1

- APPENDIX.B: ION EXCHANGE RESINS B-1

APPENDIX C:' REGENERATION PROCESS DESCRIPTION C-1

APPENDIX D: ANALYSIS OF IONS ON ION EXCHANGE RESIN D-1

APPENDIX E: RECOMMENDED MAINTENANCE PROGRAM E-1

'

APPENDIX F: CRUSH STRENGTH TEST PROCEDURE F-1

APPENDIX G: DYNAMIC CAPACITY ; LLJ PROCEDURE G-1

X
[
y

ILLUSTRATIONS

' Figure Eage

41 Flow Distributor Elements 4-2

4-2 Polisher Vessel Recirculation System 4-4

'

4-3 Resin Trap with Wedge Wire Screen.s 4-11

,
4-4 Resin Trap with Mesh Screen 4-12

4-5 Loss of Type I Strong Base Hydroxide form Anion Resin

Capacity in 140 Hours at Indicated Temperature 4-15

4-6 Conductivity /pH Relation for Ammonia 4-17

4-7 Anion Concentration vs. Conductivity of Acid Solution

at .?" 4-18

4-8 son , > anitor Calibration 4-19

4-9 Typical Condensate Polisher Resin Bed Expansion as a

Function of Backwash Water Ternperature and Flowrate 4-24

{' 7-1 -Ultrasonic Resin Cleaner 7-5

7-2 .Elution of Ammonium Ion from 8% DVB Cation Resin 7-8

7-3 Effect of NaOH Regenerant Level on Regeneration Efficiency

of Chloride and Sulfate form Duolite-A161 Resin 7-11

B-1 Variation of Re:iin Utilization with Flowrate B-4

.

B-2 Chloride Breaktarough from Powdered Resin Polishers

Operated at pH ef Approximately 9.0 B-7
,

B-3 Elution of Sodium from Cation Resin - B-9

B-4 Dowex Resin Selectivity.vs. Crcsslinkage B-10

B-5- Typical Chloride Elution Capacity of Type I Anion Resins B-11

C-1 - Conventional Regeneration Procedure C-2

xi
 ,,, , , , , , , .. . . . . . .

g.
.
.

ILLUSTRATIONS (continued)

Egure l' ARC

C-2 Ammonex Regeneration Procedure C-4

C-3 Seprex Regeneration Procedure C-5

C-4 Regeneration with Inert Resin C-6 '

L/

Xii
o

.
.-_ - _ _ - - - _ - - - - - - - _ _ _ _ _ _ _ _ _ _ - - - - _ _ _ _ _ _ . . _ _ _ . _ _ _ _ - _ _ _ _ . - _ _ _ _ _ _ _ _ _ - - _ _ _ _ _ - _ _ _ _ _ _ _ _ _ _ _ . _ _ . _ - _ - - . . _ . . _ _ _ _ - _ - . _
 . . . . . . _. . _ _ _ . . . ._ . _ .. . _ . _ _ _ > _ _ ,

TABLES

- IAhle Page

4-1 Condensate Polisher Process Vessel Instrumentation

and Samples 4-14

4-2 Deep Bed Regeneration System Instrumentation and

-
Sampling Recommendations 4-22

5-1- Powdered Resin Precoat System Instrumentation and

Samples
-

5-4

7-1 Chloride Removal with Caustic Soda 7-9

B-1 Degree of Regeneration to Achieve Sodium and Chloride

Leakage of b3 ppb B-6

- B-2 - Powdered Resin Specifications B-13

B-3 Bead Resin Specificatioris B-1S

B-4 ~ Condensate Polisher Used Resin Test B-16

E-1 Condensate Polisher System Instrument Maintenance E-4

xili
 SUMMARY

Control of impurity ingress to PWR steam generators is essential to minimize

corrosion damage. A properly designed and operated condensate polishing
systems can significantly reduce the quantity of impurities transported to the
steam generators.

Recommendations and technical justificaitons are provided for the design

and routine operation of both deep bed and powdered resin systems Specific
topics addressed include the following:
+ Distribution and underdrains systems
* Insrumentation and sampling lines
* Piping
* Regeneration systems
-
Fines filters
* Flow rates and distribution
* Precoat mixing systems
. Operator training
* Maintenance
. Flow balancing
* Regeneration and transfer procedures

S-1

- - - - - _ _ _ _ - -
 _ ___.._.-._. __ _ __.___ . _ . _ _ _ _ . _ _ _ _ ._

'

Section 1.0

INTRODUCTION

The presence of externally generated corrosion products and aggressive dissolved

solids has caused corrosion of PWR steam generators that has resulted in high costs
and reduced plant availability. A number of studies have shown that a full flow
condensate polishing system can significantly reduce corrosion product transport to ,

the steam generators. Additionally, the studies have shown that deep bed polishing
systems can provide protection to the steam generator during limited periods of
"

condenser cooling water leakage, while the leak is being located and repaired.
,
Finally, the studies have shown that polishing systems can and are designed and
operated in a manner that they can improve water purity and that they are able to
meet published PWR water chemistry guideline recommendations.

It is recommended, therefore, that all PWRs have a full-flow condensate polishing

system installed and.that it be designed and operated to provide effluent water
quality sufficient to meet the PWR Secondary Water Chemistry Guidelines under
all cperating conditions. As a minimum, the system should be operated for post
. shutdown and prestartup cleanup. The decisions regarding the system design type
and operating service will be utility and site-specific, depending on the influent
water quality design basis. Finally,it is emphasized that due to the potential for
resin regenerant chemical release, a poorly operated or designed system can cause a
significant decrease in water purity to levels known to be harmful to steam
generator materials of construction. Accordingly, the installation of a polisher
system must be accompanied by a corresponding commitment to provide the
resources and personnel training required to provide the necessary attention to
operation.

1-1

-- - - . . . . - - _ = . - .
 -
- _ _ ____ - - _- ___ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _

Section 2.0

SCOPE AND APPLICABILITY

A wide variety of condensate polishing systems and resins have been used
successfully in condensate polishing applications. The goal of this guidelina is to
provide recommendations to ensure the polisher system effectively controls steam
generator impurity ingress consistent with industry water purity goals.
'

The recommendations include the following system parameters:

,

,
o Design and Layout of VesselInternals

* Operating Parameters

* Resin Performance

o System Monitoring Instrumentation

* Equipment and Instrument Maintenance

The guidelines do not cover design aspects such as structures, pressure boundaries,
*
detailed system layout and material selection. These features do not r,ignificantly
affect system performance, which is the main focus of these guidelines.

2-1

.
_ _ . ___ __-__________ ___
-_
. . .. .
- , . . - . - - - - - - - - - - ... - - - .-

SectN 3.0

DEFINITIONS

Air Scrubi Upflow of air through a resin-water mixture to assist in releasing

particulates from resin surfaces. Normally employed as an early step in the
regeneration process.
-
Ammonia Cycle: _ The operation of a cation exchange resin wherein the removal of
specified cations from the influent water is accomplished wherein the removal of
specified cations from the influent water is accomplished by exchange with an
*
equivalent amount of ammonium ion from the cation exchange resin.

All-Volatile Treatment (AVT): Addition of volatile chemicals to-power plant

condensate to control pH and oxygen concentration. Ammonia and hydrazine are
| the most common pH control chemical and oxygen scavenger, respectively.

Anton: - A negatively charged ion, such as chloride, sulfate, nitrate, carbonate, etc.

- Anion Collector: A system of laterals used in mixed bed demineralizers to remove

the anion resin layer off the top of the cation resin. It is located at the interface
between the seperated cation and anion resin.

Anion Exchance Material:- An ion exchange material capable of the reversible

exchange of negatively charged ions.

Anion - Rssity

Weak Base _-A resinous ion exchange material containing amine functional groups.
-
It has little,if any/ salt-splitting capacity and can remove anions only from strong -
acids.

Sjrpnglasg - A resinous ion exchange material containing the highly ionized

, J quaternary ammonium functional group. It can remove anions from acids and'
neutral sal'-

. : Backwash: - The upflow of water through deep bed polisher resins to fluidize the
resin beads and flush loosened suspended solids out of the resin. Also, the reverse
flow of water through the filter elements in a powdered resin polisher to remove
.

the precoat and associated suspended solids.

Breakthrough: The first appearance of ions from an ion exchange bed, other than
those used as regenerant. Breakthrough generally indicates that regeneration of the
resin is necessary.

3-1

. . . -
- . .- -. . . ..
 Djlen: A positively charged ion, such as sodium, calcium, ammonium, -
magnesium, etc.

Cation Condu'ctivity: Conductivity of a solution after the cations have been

removed by passing the solution through hydrogen form cation resin.

Cation F.xchange MateyJal: An ion exchange material capable of the reversible

exchange of positively charged ions.
.

Qtion Resin:
'

Weak Acid --A lesinous ion exchange material containing the weakly ionized
carboxylic acid group. When used in the hydrogen form, this 1asin has negligible
salt splitting capacity and can remove monovalent cations only from highly basic
solutions.

Strong Acid - A resinous ion exchange material containing the highly lonized
sulfonic acid functional group. It can easily split salts converting them to acids,
i'

Channeling: Cleavage and furrowing of the resin bed due to faulty design and/or
operational procedures, in which the solution being treated follows the path of least
resistance, runs through these furrows, and fails to contact active groups in other
parts of the bed. j

Conductivity: The electrical conductance of a solution is merely the reciprocal of the

electrical resistance. -It is measured by the. quantity of electricity transferred across
unit area, per unit potential gradient per unit time. The conductivity of pure water
:such a.s condensate is normally expressed as umho/cm or uS/cm.

Crosslink:- Linkage between two or more polymeric chains at sites other than those
- at the ends. Crosslinkage of organic polymers takes place during resin manufacture
to develop insolubility and enhance physical stability. Decrosslinking during
service degrades resin performance.
.

Deep Bed Polisher: _ A polisher vessel containing a column of ion exchange resins 3
feet (~_1 meter) or more deep. The deep bed provides a relatively large ionic holding |
capacity'and 'aiso provides a long enough ion exchange path to provide good ion -

exchange efficiency.

Dissolved SolidsL Impurities such as salts and silica _which have gone into solution. |
'in water.
_
_ _

3-2

-- -. . _ _ _ . - .-
 ___ . _ _ _ . _ _ _ _ . ._ _

pistributor Unlet): A mechanical system generally located at the top of an exchanger

through which the influent enters the vessel for processing. When located at the
top of a regenerable vessel, it may also act as a collector of the backwash water which
is discharged to waste It serves to prevent disturbance of the top of the resin bed
due to impingement by introducing the influent evenly over the surface of the resin
bed

'
Distributor (Outlet): A mechanical system generally located at the bottom of a deep
bed exchanger through which the processed water (effluent)is collected from the
resin bed on a uniform basis with respect to the entire cross section of the exchanger.
,
It may also serve as the distributor for resin backwash water and resin mixing air in
--a regenerable vessel.

Distributor (Regenerant): A mechanical system through which the regenerant

solution is introduced uniformly to the entire cross section of the exchanger for the
- maximum utilization of the regenelant solutions.

Efficiency: The effectiveness of a condensate polisher for removing influent -

- impurities during operation. Also, the effectiveness of the regeneration process for
_

removal of impurities from the resin.

End Point: Maximum acceptable concentration of a particular impurity in the-

polisher effluent at which the service run should be terminated.

Eauilibrium: When the ratio of ions in solution to those within the resin structure
is equal to a constant value determined by the resin properties.
Enhaustion: The state in which the resin-is no longer capable of useful ion
'xchange; the depletion of the exchanger's supply of exchangeable ions. The
exhaustion point is determined arbitrarily in terms of: (a) a value in parts per -
billion of ions in the effluent solution, (b) the reduction in quality of the effluent
water determined by a conductivity bridge which measures the electrical resistance
of the water, or_(c) any other suitable criterion.

. - External Regeneration: A procedure in which the ion exchange resin is sluiced or

transferred (hydraulically, pneumatically, or by gravity) after exhaustion into
- another vessel wherein regeneration occurs.
.

Freeboard: The space provided between the top of a resin bed and the inlet
distributor of an ion exchange vessel.

Hydrogen Cycle: The operation of a cation exchange resin wherein the removal of 1

specified cations from the influent water accomplished by exchange with an l

equivalent amount of hydrogen ion from the exchange resin.

I
I
!

3-3
I
,
 . . - - . . -- -- - .- - .- - . .. _- .
-- _

Ion Exchange Capacity (Volume Basil): The number of milliequivalents of

exchangeable ions per milliliter of backwashed and settled ion exchange material in
. Its standard form.

Ion Exchange Capacity (Weight Basis): The number of millicquivalents of

exchangeable ions per dry gram of ion exchange material in its standard form.

-Ion Exchange Resin: A synthetic organic lon exchange material, usually in spherical
form. See definitions for anion exchange and cation exchange material. -

Leakage: The amount of salt or containment present in the processed, effluent ,

water. May be expressed as a percentage of inlet concentration, or in effluent

concentration as part per million (ppm) or part per billion (ppb).

Operating Cycle: An ion exchange process consisting of a regeneration phase and a

service run.
.

: Osmotic Shock: A rapid change in osmotic pressure usually caused by change in

liquid medium ionic concentration, such as from water to regenerant solution.

Powdered Resin: Norraal ion exchange resin which has been ground to a U.S.
Standard mesh range of 200 to 600.

Powdered Resin Polisher: A polisher which operates on the same principle as a

precoat filter, except the filter medium is powdered ion exchange resins. The
powdered resins purify water passing through them by filtration and ion exchange.
These units have lower ion exchange capacity than comparable-size deep bed units
oecause the amount of resin used in the precoat is less.-

.Precoal: Powdered filter medium, such as Solka-Floc or powdered ion exchange

resins, which is coated onto a filter-type element or septum. ; The filter medium
forms a relatively thin. layer and is held in place by differential pressure. It is
,
removed by backwashing the element.
'

Regenerant: The' solution used to restore the activity of an ion exchanger. Acids are
employed to convert a cation exchanger to its hydrogen form. The anion exchanger
1may be converted to its hydroxide form by treatment with an alknline solution. .

Regeneration: Restoration of the activity of an ion exchanger by replacing the ions

removed from the treated solution with ions that were on the resin prior to
.exh'a ustion.

3-4

a- +.,-
 ._ _ _ _ _ _ _ __ _ _ _ _ _ _ . _ _ . _ _

Regeneration Level: The weight of regenerant used per unit quantity of icn
exchange material in a single regeneration. It is usually expressed in terms of
weight of regenerant (as 100 percent) per unit volume of fully hydrated ion
exchange material, in a specific ionic form, measured after backwash and draining.

Resin Fouling: The absorption of foreign matter by an ion exchange resin resulting
in impairment of resin performance. Types of fouling include surface and particle
coating by products of steam / water loop corrosion (crud), and loading with some
*
organic acids, bacteria, iron, regenerant impurities and oil.

'
Resin Selectivity: Relative affinity for ion exchange of various impurity ions in
exchange resins, hence degree of attachment of ions to resin sites (during service
and regeneration). Selec&ity generally increases with valence and decreasing
hydrated-lon size.

Resin Separation (Backwash): Hydraulic separation of the anion resin from the
; cation resin by backwashing.- Separation is due to the differences in specific gravities
..a particle sizes of the anion resin and cation resin; normally the anion resin being
lighter will be lifted to the top of the cation resin.-

-Resin Strainer (Resin Trap): Strainer used to prevent discharge of resins from the
exchanger . vessel into the feedwater system in the event of failure of the outlet
distributor.

Rinse: That part of the regeneration phase of an ion exchange process in which
water is passed through the bed of ion exchange material to remove the produced
salts and residual _regenerant solution. The rinse is continued until diffusion from
_

,
within the resin beds is completed to the necessary level.

| Rinse __ Requirement: Measure of the volume of water used during regeneration

j ' before a resin can be put into service. Rinse requirements may be increased by
| _ employing impure grades of regenerants, hydraulic channeling, contamination,
L fouling or deterioration of the resin.
~
|
LSeptum: A structural tube with fine perforations, which is coated with a filter
. medium such as powdered resin in a. condensate polisher vessel.
1 .

E
Specific Conductivity _: Refer to " conductivity" definition. _

| Service Run: That part of the operating cycle of an ion exchange process in which
water is passed through a bed of the ion exchange material to exchange specific ions
from the water for an equivalent number of specific ions from the ion exchange
material.
|

|
3-5
|

. -
 ._ _ _ . . _ . _ . . _. _ _ . . ~. _

:-gyspended Solids: Particulate material suspended in water generally consisting of

steam / water cycle corrosion products and insoluble organic material.

Throw: Release of regenerant or other chemical species from resins during the
service run. : Also, leakage of resinous materials from the condensate polisher into
the system.

Underdrain: Refer to " Distributor" (Outlet) definition. .

3-6

,- , - - . . , _ _
._. _ _ _ ____ _ ___ _ ____.
 Section 4.0

DESIGN CRITERIA: DEEP BED POLISHER SYSTEMS

4.1 SERVICE VESSELS

4.1.1 Influent Water Distribution

'
Recommendation. The vessel influent water should be distributed over the entire
area of the polisher vessel such that uniform flow through the bed is provided and
the water flow does not fluidize the top of the resin bed.
.

.lustification. The inlet distributor works in conjunction with the underdrains

to provide uniform flow across ;he entire area of the resin bed. Most condensate
polishers are designed for flows of up to S0 gpm/sq ft and proper design of the inlet
distributor prevents jets and eddies that fluidize the resin bed. When the resin
becomes fluidized, particulate matter penetrates deeper into the bed and causes
nonuniform flow over the surface area. Also, the ionic impurities contained in the
influent water do not contact the fluidized resin and, hence, no ionic exchange can
occur. Improper design of the inlet distributor could result in shortduration runs
due to poor effluent quality or high vessel pressure drop.

A variety of distributor designs have been able to provide this even distribution
criteria. Some proven designs are illustrated in Figure 41; the variation is based on
differences in vescel dismeter and water column height between the distributor and
the top of the resin bed. Figure 4-1b is a schematic of a distributor with a hub and
radiallaterals. This design has been used effectively only in small-diameter (<5 ft)
vessels because distribution uniformity decreases with increased distance from the
hub.

4.1.2 Underdrain Design

Recommendation. The polisher vessel underdrain design must provide uniform

flow across the entire resin bed, complete removal of exhausted resin for
-
regeneration, protection from resin plugging, and sufficient support to withstand
expected weight and hydraulic forces.
.

4-1

-
 .. . .- .- .. -

I I

I I
i I
' '
i i Note: Doublet inlet for high
' '
' ' flowrates used in the polisher
;i vessels (~50 gpm/ft') would
' I make the distributor more
' '
i i effective,
' '
, , .

I I

I I
I I

i i .
, ,

' '
, i

a) Header with Parallel Laterals

I i

J
b) Hub with Radial Laterals

'

c) One Diffuser-Type Nozzle Used in Multiple

Attached to Pipin[; Array

Figure 4-1. Flow Distributor Elements

4-2
 .~ . -.-- . . - - -- - .

lustification. Uniform flow across the resin bed is an important design criteria for
the polisher. (see 4.1.1).

When the resin bed effluent no longer meets water quality requirements, the resin
is transferred to the external regeneration system. In this system the resin is
hydraulically separated prior to the addition of regenerant chemicals. To prevent
contamination of the resin with the wrong regenerant, the two (or three) resins
interface. For this to occur consistently and predictably, a complete resin transfer is
-
essential. Hence, the design requirement for complete resin removal.

If improperly designed, resin can be forced by the service water flow to plug the
~
underdrain, preventing uniform flow across the resin bed surface. Likewise, the
weight of the water and resin and the hydraulic forces can materially damage
underdrains without weight / force design criteria.

L A flow deflector on the vessel outlet nozzle to improve flow distribution is also
recommended.

4.1.3 Sight Glasses

Recommended. Sight glasses should be installed just above the bottom support
plate, at the resin interface (s), and at the top of the resin bed.

Tustification. Proper water distribution, complete resin transfers, and proper anion-
cation resin separation can be verified by viewing through strategically placed sight
-glasses. Operator vision is often impaired by fouled sight' glasses or poor lighting.
The installation of multiple sight glasses at critical viewing elevations can
Lovercome the lighting concern and decrease the reliance on one, possibly fouled,
sight glass. Consideration should be given to installing three glasses (-120 degrees
apart) at each of the recommended levels.

4.1.4 Recirculation System

,
Recommendadan. A condensate polisher vessel recirculation pump (Figure 4-2),
capable of near-normal operating flow rates should be installed.

. ,1ustification. Once condensate passes through the condensate polishers there is little
that can be done to prevent it from reaching the steam generator. Likewise, when
the effluent does not meet desired water quality, there is little that can be done to
prevent downstream contamination. A recirculation pump can be used to purge
the ion exchanger of aerated water prior to service flow, to provide flow through the
resin until satisfactory water quality can be assured, and to maintain the ion
exchange dynamics at times when condensate flow through the vesselis not
desired.

4-3

.- - - - - - ._ ..-
a

Condensate
'
'
:

:
I

XI I
-

/
Polisher Polisher
Vessel Vessel
(in Service) (to be Placed
in Service)

n Recirculation
Pump

k# \_/
v
Ak
,, | ,,

17 1P
b Jk

,
,r
i

Pctished Condensate -

Figure 4-2. Polisher Vessel Recirculation System ,

4-4
 _ .

Withcut a recirculmion pump, impurities are released from ine bottom layers of
freshly regenerated resir.s when the bed is first put into service (L2). A bigh flow
rate recirculation tystem will transfer taese contaminants to the top of the polisher
bed, thus mininiiting chemistry transients associated with new senice cycles.

.In addition, subjecting the resin to near system recirculating flows will likely
prevent the resin spike that has been found to be typically esociated with initial
cperation of a freshly regenerated bed Q).
.

4.2 CATION REGENERATION AND SEPAR ATION VESSELS

.

4.2.1 Underdrain for Cation and Separa:' en Nessels

Remnunenhd. The underdrain must be designed to provide uniform flow during

the up-flow backwash aperation, and the down flow regeneration and rinse modes.
~

htsillintian. Uniform backwash flow will allow a level interface to develop

between the separated cation and anion resins, which is critical for proper operation
of the polisher. In addition, complete removel of resin from the vessel must be
possible during the resin transfer step.

The underdrain also scryes to collect tegenerant ano mse water. During these
operations, uniform flow distribution is also required. Appendix n presents a
discusrion of underdrain designs.
,

4.2.2 Cation Vesse! . nfluent Water Distribution

Rcrommended The vessel influent rinse water should be distributed over and the
backwash collocted from the entire area of the cation vessel to provide uniform
flow,

hull 11 cation. The justihcation lie d in Section 4.1.1 is also applicable for the
,
co', lector design.

4 23_Sunplinghncitalian
.

Retemmrahllon. A sampling penetration should be installed for sampling the

interface utaween the cation and anion resins (or other resin interfaces).

Justification. The volume of resin in individual charges varies because of

incomplete transfers and operational resin losses. As a consequence, the level of the
interface between separated resins varies with time and can be above or below the
design interface level. When the interface varies the regenerant chemicals can
contact the improper resin beads and serious contamination will result. A sampling

4-5

i
;
_
 . - - . - - _ _ - _ - . _ . . . ~ - . - _ - _ . - . __

penetration permits the remont of a resin sample following separation. When the
interface is found to unacceptable, resin of citi.w type can be adc ed or removed to
return the interface to the proper level.

4.2.4 Dhidhulina.olAcid

Recommendaljon. The acid distributor laterals or nozzles should be designed for

uniform acid distribution across the resin r,urfare.

Jus 1Ricadon. Maximum regeneration efficiency is obtained by exposing all resin to '

-regenerant chemicals. Locating the acid distributor immediately above the laterals
to which the anion collector droplegs are attached keeps the distributor close enough ,

to the resin surface for good acid distribution. The distributor requires a sufficient
number of !aterals or nozzles to supply acid uniformly to the top of the resin bed.

4.2 5 Cation Resin Takeoff

Jtecommendalinn. The cation resin take-off should ba designed so that complete

removal of the cation resin from the vessel is routinely possible.

.lustifiention. As previously mentioned, complete resin transfers are important

for maintaining resin mixtures and resin separation interfaces. If the vessel has a
flat screen type resin support and has a take-off located at the vessel centerline,
complete removal has been shown to be routinely pos31ble.

4.2.6 Sight Glasses in Callon Vessel

Eccommeridadon. Sight glasses should be installed just above the bottom support
plate, at the resin interface (s), at the top of the resin bed, and at the top of the vessel.

Jusuncalon. Proper water distribution, complete resin transfers, and proper anion-
cation resin separation can be verified by viewing through strategically placed sight
glasses. Operator vision is often impaired by fouled sight glasses or poor lighting.
The installation of multiple sight glasses at critical viewing elevations can
overcome the lighdng concern and decrease the icliance on one, possibly fouleu, ,

sight glass._ Sight glwes at the top of the vessel are recommended to determine
anion level during the hydcaulic separation backwash operation. Consideration
thould be given to insulling three glasses (-120 degrees apart) at each of the -

reconmended levels.

4-6

-
 _ _ _ _ _ - _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ - _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ - -

4.3 ANION VESSEL

4.3.1 Underdrain of Anion Vessel

Recumturndation. The underdrain should be designed to provide uniform flow

du7ing the regene:ation and rinse modes and should permit complete removal of
resin duting the resin transfer operation.
4

.
lukillication. The underdrain serves to collect reganerant and rinse water. During
these operations, uniform flow distribution is required for maximum regeneration
efficiency. In addition, complete removal of resin from the vessel must be possible
, during the resin transfer step to insure resin mixture and interfaces remain
constant. Appendix A presents a discussion of underdrain designs.

4.3.2 Einsdaterllhttilmilon
Recommendation. The vessel influent rinse water abould be distributed -

over the entire area of the anion vessel to provide uniform flow.
:

Justificatinn. The justification !!sted in Section 4.1.1 is also applicable for the
distributor design.

4.3.3 -Resin Addition /lismoval Penettailon

Rcrommendation. A penetration should be installed to permit the addition or
removal of anion resin.

IU111ficallon. The volume of resin in individual charges varies because of

incomplete transfers and operational resin losses. As a consequence,it is frequently
desirable te make adjustments to the anion resin inventory. A convenient access
penetration minimizes the impact of such an operation.
4.3,4 Caustic Distributor Laterals

Recommendation. The caustic distributor laterals or nozzles should be designed for

uniform caustic distribution across the resin surface.

lustification. Maximum regeneration efficiency is obtained by exposing all resin to

'

regenerant chemicals. The caustic distributor should be located close enough to the
resin surface for good caustic distribution. The distributor requires a sufficient
number of laterals or nozzles to supply caustic uniformly to the top of the resin bed.

4-7

|
i
- . - - - - - + . . _ . . - ,_, . - - . . - _ _ _ _ _ _ _ _ . , , , ,
 . - -. .. _. - - - _
- - - - _ - - . - - _

.. 7

4.3.5 Aninn_ResiiLTake:off

8cconunendalinn. The anion resin take-off should be desi;;ned so that complete

removal of the anion resin from the vesscl is routinely possible.

Justification. As previously mentioned, complete resin transfers are important for

maintaining resin mixtures and resin separation interfaces. If the vessel has a flat ;

screen-type redn support and has a take off located at the vessel centerline, complete
removal has been shown to be routinely possible.

4.3.6 Sjglit Clt.sses in Anlon Vessel '

'

Reconunendallon. Sight glasses should be instalkd just above the bottom support
plate, at the top of the resin bed, and at the top of the vessel.

lttsillicallon. Proper water distribution, complete resin transfers, and proper anion
resin inventory can be verified by viewing through strategically placed sight glasses.
Operator vision is often impaired by fouled sight glasses or poor lighting. The
installation of multiple sight glasses at critical viewing elevations can overcome the
lighting concern and decrease the reliance on one, possibly fouled, sight glass.
Consideration should be given to install!nt; three glasses (~120 degrees apart) at each ..

of the recommended levels.

Sight glasses at the top of the vessel are recommended to determine anion
inventory and proper caustic distribution. Since an air scour and backwash are
performed to remove deposits from the anion resin beads,it is desirable to have
sight glasses at the top of the vessel to observe the operation.

4.4 MIX AND STORAGE VESSEL

. 4.4.1 S1orage_Ecssel Underdrain

Recommendalinn. The underdrain must be designed to provide uniform flow

during the mixing and rinse modes.

Jusillicallan. The justifications presented in Section 4.1.1 and Section 4.1.2 apply to
the inlet distributor and underdrains for the mix and storage vessel. The structural
design criteria described in Section 4.1.1 also apply to these components. .

- 4.4.2 Sintage_Yessel Resin Take-off

Recommendation. The resin transfer take-off should be designed so that complete

removal of the resin from the vessel is routinely possible.

IJ

_ __ ~ _ .- -
_

justification. As previously mentioned, complete resin transfers are important for

maintaining resin mixtures and resin separation interfaces. If the vessel has a flat
screen t)pe resin support and has a take off located at the vessel centerline, complete
removal has been shown to be routinely possible.

4.4.3 Slonige Vessel Sight Glasses

Recentmendatlan. Sight glasses should be installed just above the bottom support
,
plate and at the top of the resin bed.

Intification. Proper water distribution, complete resin transfers, and support plate
, integrity can be verified by viewing through strategically placed sight glasses.
Operator vision is often impaired by fouled sight glasses or poor lighting. The
installation of multiple sight glasses at critical viewing elevations can overcome the
lighting concern and decrease the reliance on one, possibly fouled, sight glass.
Consideration should be given to installing three glasses (~120 degrees apart) at each
of the recommended levels. s

4.5 IlEGENEl(ANT CllEMICAL SYSTEM

4.5.1 Sutem11aterials of Consitnctioll

Recomniendation. All system materials should be designed to be compatible with

the various concentrations and mixtures cf regenerant chemicals.

Julification. A major problem encountered with condensate polisher regenerant

chemical systems is the corrosion of equipment and piping. Corrosion is primarily
the result of improper materials selection for the application. The regenerant
chemicals (normally sulfuric acid and sodium hydroxide) are strongly corrosive.
Attention to materials of construction is required in the original system design to .

avoid high maintenance costs.

4.5.2 Ecgenctant.Aietering Puntpa

-
Ecconimendation. Regenerant metering pumps should be positive displacement
pumps with pulse dampeners.
-
Justification. The regenerant chemicals are generally stored in the concentrated form
and are diluted by mixing with water a.; the chemical is being added to the
regeneration vessel. Positive displacement pumps have been found to be least
susceptible to corrosion.

4-9

. - _ _ _ _ _ _ _ _ _ _
 - - - . - . - - - _ - - - - - _ - - - _ - . - .. - _ - - - . - - . .

4.6 PIPING, VALVES, AND RESIN TRAPS

L

4.6.1 l'iphigAlatrilals of Constnttilon

Recommendallon. Piping should be constructed of, or lined with, an appropriate

corrosion resistant material,

lustification. Improper materials selections are often the cause of costly post- .

operation maintenance. The choice of marginally corrosion resistant materials

*
!

initially for economic reasons will certainly lead to higher operating and
maintenance costs. .

4.6.2 Syitem Layoul

Recomruendation. The system layout should be designed to provide easy access to

valves for maintenance or replacement.

Justificatien. Despite the effort placed in the selection of compatible materials,

valves are typically a major source of operating problems. Because of this need for
frequent maintenance, the layout of the system is important to minimize the
maintenance effort and system reliability.
'

4.6.5 Resin Tran Desien

Recommendation. If rest raps are designed in the polisher effluent lines, the traps
should be designed to be .idily backwashed, capable of taking a large pressure drop
when clogged, and located for easy inspection and cleaning.

Iustification. If the resin traps are not designed to withstand the pressure drop
resulting from the collection of large quantities of resin, they will permit the system
damage that they were designed to prevent. Typical resin trap designs are presented
in Figures 4-3 and 4 4. Results from resin leakage studies performed by the Steam
Generator Owners Group indicate that resin traps are ineffective in preventing the
low-level resin leakage associated with normal operation Q). The traps are designed
with relatively coarse screens and will not retain resin fines.

Interference from pipes. valves, etc. often make it difficult or impossible to .

disassemble resin traps for inspection and cleaning. Resin traps can be a source of :
resin or crud bursts if not properly designed, cleaned, and maintained.

!- . 4.6.4 Resin Fines Filters

Itecomntendalian. Resin fines filters,if desired in the system design, should be

compatible with system pressure drop concerns.

4-10 h

,,m-~,,._._.-. . - _ . - - - . . - - - , - _... . . . . _ . _ . - . . . - - - , , - . - - - . . _ . , , ._--__._.--,,-,..,.-....__-~-J

 _-_

outlet
-

^
7

. . _

N $ ,A A A _L n 'V

V| .
~
=
9|
nackwash inici

p- =

wedge wire
screen.

+
inh 4
_ _

Dackwash Outh4

Figure 4-3. Resin Trap with Wedge Wire Screens

4-11
 - . ..- _ . - _ ._ .

Outlet ,

UZ D
Q
3
e rx x =r- u .. _ .+.,
(-.-)
u
'
D.;mm.hm( .g
.

inlet '' N rW.

- -- %~ .-
,y)
- -
"I . _ . ,
-. ;r
u p.m/2tCN
m_ y _f _'T***
..gENC
g w .

3, '
(I I

Perforated Backwash
Metal inlet

Mesh
Exbandal
etal screen

Figure 4 4. Resin Trap with Mesh Screen

4-12
 jusilucation. . To date there is little operational experience with resin fines filters.
There is si;;nificant industry concern over the ability of condensate polishers to be
operated full flow, full-time with steam generator degradation due to sulfate (resin
throw). -

4.7 INSTRUMENTATION

4.7.1 Operrtional Process Instrumentation

4

Recommendauen. The condensate polisher systcm should have adequate process

,
and' chemistry ins,trumentation to keep plant personnel apprised of system
.per formance.

fustificathm. Table 4-1 describes the minimum instrumentation recommended to

maintain awareness of system performance.
'

1) Pressurg - Operators should be able to check system pressurcs and differential

pressures at all times. It may be necessary to remove polisher vessels from service
because of high differential pressure, particularly during periods of condensate high
suspended solids level. High strainer differential pressure will necessitate
backwashing, and possible strainer maintenance and anderdrain inspections.

Standard dial-type pressure gauges are satisfactory for the recommended condensate
polisher vessel pressure indicators.

2) lemperature - Anion capacity loss is a:celerated by increasing temperature

-(Figure 4-5) (4) The capacity loss may result from conversion of strong base ion
_

enchange sites to weak base groups or from complete loss of ion exchange groups.
The capacity decline rate induced by temperature increases normally is higher
initially than that observed over an extended time at a given temperature.
Resin manufacturers generally quote a maximum operating temperature of 140 F
(60'C) for anion resins typically used for condensate polishing. Since Figure 4-5
indicates a significant capacity loss at 140 F even after a short period, it is important
to monitor condensate temperature and maintain temperature as low as possible to
minimize anion resin degradation.

. Otherwise, et accelerated anion resin replacement schedule will be necessary to

achieve maximum benefit from the polishers.

3) Flow TotalizcI- Total condensate volume processed per polisher vessel service
cycle should be monitored and recorded. Changes in obtainable condensate volume-
per service cycle could result from changes in condensate chemistry, resin
performance or deep bed system resin regeneration inadequacies.

4-13

_. . . . _ __ -- _ _ _ _ _ _ _ . _ _ _ __ -._ ._ _
 Table 4-1

CONDENSATE POLISHER PROCESS VESSEL INSTRUMENTATION Af40 SAMPLES

Condensate Individual Vessel

Parameter h1xed Inlet Mixed Outlet Inlet Across Outlet St rainer
Pressure Xi XI XI
.

Differential Pressure XI XI

Temperature 1,1 ..

'
Flow Totalizer XI

-Flowrate X1RC

Specific
Conductivity XlR X1R X1R

Cation
Conducti vity X1R X1R XIR

. Chloride and
Sulfate G G G

Sodi um XlR XlR- XIA

Silica XI- XIA X1A

0xygen X1R XI

c.
X = Instrument
~1 = Indicctor
R = Recorder.
C = Controller
'
G = Grab Sample

, A = Valving available to select mixed outlet and/or individual vessel outlets-

4-14
 I

l
|

100 | | | |
,

-
-
. 80

~
60
e
.h
i
O
N ~
~

& 40
so

i
ti
2
.3 ~
-
20

#
,
0 I H I I

0 20 40 60 80 100:C
68 104 140 176 212'F
* Tc:nperature

| . Figure 4 5. Loss of Ty 3e 1 Strong Base Hydroxide form Anton

Resin Capacity in 140 Hlours at Indicated Temperature
'

|-

|
|

.
4-15
1.

i
|.
|- . _
.
. - . . . .. . . _
- . - , . .
 _ ____ . _ . _ . _-. - -
_ - _ .
- - --- _ . __ .__..___.

4)ynst Flmy.J4k - The operators need to know the flow rate and pressure drop ,

| . across each polisher vessel to decide when to start or stop vessel service cycles. Flow ;

controllers on the inlet of each vessel are for balancing the flow through each vessel.

5) Specific Conductivig Condensate polisher inlet specific conductivity essentially

will be equivalent to the ionized ammonium hydroxide concentration and,
therefore,is related to condensate pli (Figure 4 6). The outlet specific conductivity
-
of polishers operating with ammonium form cation resin also can be correlated to
pil. For polishers operating in the 1.ydrogen cycle, the outlet specific conductivity *
,

gives an approximate indication of dissolved solids impurity level.

F
'

Measurements of plI in water of low conductivity, such as treated power plant

condensate, armally are inaccurate. An alternate method of monitoring and
controlling pli is specific conductivity. Normal levels of Jonic impurities in
condensate are negligible, and pil as a function of conductivity will be as shown in
'
Figure 4-6;

'
6) C.Mifn Conductivig - A sample of polisher efflaent flows through a small
'
column of hydrogen form cation resin and the column outlet conductivity is
measured. Called (hydrogen) cation conductivity, it identifies total anionic
impurities. To be entirely meaningful, thermostatic control of sample temperature
is necessary. Callon conductivity is a mningful test on secondary cycle water. As ;

shown in Figure 4 7, cation conductivig increases rapidly with anion concentration.

However, below 5 ppb the ability to measure anions is limited because of .

conductivity arising from the dissociation of water.

7) Chloride and Sulfale - The best currently available method for measuring
- chloride and sulfate concentrations in the sub-ppb range is lon chromatography.
Available instruments are designed as a laboratory tool and not as a process
'
- instrument. When sampling and analysis are performed carefully, chloride
- concentrations down to 0.1 ppb and sulfate to 1 ppb easily can be determined by lon
chromatographic analysis. Approximately 20 to 30 ml of sample must be
concentrated on a concentrator column to achieve the noted detection levels. .

Sample colhiction and analysis procedures are discussed in Reference 5. .

8) Endium - Trace concentrations of soditim can be measured potentiometrically

with a sodium-selective electrode. Amines are added to the sample stream to raise -

pil to >10.5 to minimize hydrogen ion interference. Although potentiometric '

analyzers are accurate for sodium concentrations of a few ppb, the results tend to be
biasect high below approximately 2 ppb (Figure 4-8). Interference from ammonium
ion and alkali metals dissolving from the glass membrane contribute to this bias
(6,Z). Performance of the reference electrode also can cause high readings at low ,

concentrations. :

4-16

w-yvee - y:----+-ry--,, ,y on., , ,-,3w,,.r--- y.,,9,.q,--....i.tw.,y, - - , - -. c .m.~co,,.-=,mu,..c ec,-, e . -m w,, ,m. ,w.-,.-mge,--~,... =m--
 . . . .- ._- - - - - . .....- - - .-- - . ...-_.- .- - - --.-. ..- -:-,. . . _ . . - . . - . - . - .

|
<

o
~ '
| | |
,

t
,

i
. i
,

..

'
to
- -
,

i
wo
c
O ,
'D
en
T
M
Z
n.
.'

|c N ,

" D .
'5
g.
D
'O
- -
co ,

U
E
i::
r

- .

,
,

'
-l l I ~
-.
o- o o.
- -
o
- -
-
- o
.
o. ,

, '
o '
'
i
1
m>/sn %n)pnpuoa slJpads i
|

l
.

'--
4 17
..

y , .-e , - - , , ,,,,~.,,,-,--,v,-yw+-,,,-v- , -~ ---r--..,.c . - ,-,.y .

-
,cm-,,ve,vv. ,,%...,..wm,+--,-w,w.wr+=,w. v w we*w-wn-
 . - - - - _ - - -
_ _ _ _ _ _ _ _ _ _ _ _ .

o
i I 1
S
|

- - o

u
o
b'
g *
.

o
r B
^ d
p %
" -
N c
0
VU
G
Q i

8 n
1,. nv4 ~C
,

e o
- , o .'f. b 'n .
- -s p
a +-
i
*
CO
,
om
d c 'O
s .
.9 4 .

- - -
a
4
E
Po
c:

- - ~
9

e m
I I
~
d, 1 -

o
m
1
- o o o
||
| uo/sn% panpunpuopr3

4 18

= - . - . - . - . - - . . -. , . - _ , - . . _ . . - _ . . .-. .- . - - - . -.
 . _ . - . . _ _ _ _ _ _ . _
_
_ . _ - . _ _ _ - . _ - _ _ . _ - _ . _ _ _ . . _ - _ _ - . _ - -..___
_ _ _

l
,

i 3 1 I | 1
| |

.
-
$
,

,
- -
3

5' o n ,

c O
b- ,3
N
*n '
t

g
E hr p
-
o
'
Oj y-) - o
k8
'
j
g 2 -5 w
4)2 mA "
Q ,2,
i

i-

- o . e, L ;
O h O
4
l 3
\
g
H
5
| -

f
.

-
dP g
- N O .

N .s
y 4
-
o \ -
-- 'I '
.

\. g- ,

s m
-
O \
-
9
o
\
\

-
\ -
9
o j
'
\
|' \ -

g
-

l )
L i e I i i
e i
i

!.
i
',eo- -
-A
o o
N
o
- '
m N -
m.
o
m.
o o
.
.

qdd 'Sulpray SuponuoH wn}pos

4-19 i

_ . , . . . . . - . , . . . _ . . - . . . . _ _ _ - - - . . - - - . . . , - . _ .
-- ~ .- ~. . - . - . . ~ . . . . _ . _ . _ - - - . , - . . _ _ . . _ . . .
.
-

Although sodium specific lon electrode monitors will indicate coacentration

changes of 0.1 to 0.2 ppb, substantial errors in absolute value may exist below 1 ppb.
Absolute concentrations can be obtained if the monito. bias is known. Flameless
atomic absorption spectrophotometry can measure sodium concentrations down to
approxi.nately 0.05 ppb and therefore provides a means for determining specific ion
electrode monitor bias.

One problem encountered with sodium specific lon electrode monitors in power
plants is iron fouthag of the electrodes the severity of the problem varies with the
quantity of suspended solids in the sample. Particulate deposition on the electrode
can be minimized by filtering the sample stream. When samples were filtered, no '

sodium monitor performance degradation was evident after six months of

monitoring condensate polisher systems (E).

9) $)ka - Monitoring silica is not too important for HOll polisher operated to the
ammonia break. For ammonia cycle operation, such as with powdered resin
systems, silica monitoring becomes very important because silica efficiency decreases
at high pil. Monitoring the polisher system inlet for rilica permits early detection of
silica ingress either from contaminated makeup water or from condenser cooling
water inleakage. Prompt identification and correction of the problem minimizes
feedwater chemistry upsets. Silica monitoring of the pollsber system mixed effluent
provides warning of silica breakthrough. The ability to switch the monitor to the
outlet of individual polishers allows quantification of individual polisher
performance,

Continuous silica monitors measure only reactive silica. Nonreactive forms (such
as colloidal silica) can be determined using appropriate wet chemical techniques L9).
Occasional checks of non reactive silica should be performed.

10) Oxygen - With ammonia present in condensate, air inleakage becomes very
detrimental because carbon dioxide in the air reacts with the ammonia to form
ammonium carbonate of bicarbonate. Thus, the ionic load for the anion resin will
' be primarily carbonate rather than salts from cooling water inleakage and other
sources. Carbon dioxide is a particular problem during long ammonia cycle runs . ;

because the carbonate can displace silica, chloride, and sulfate. Air inleakage, and
!
| thed re condensate oxygen level, should be kept to a minimum by maintaining a
tight condenser. An increase in condensate oxygen concentration is a warning of .

possible problems with carbonate anion loading.

4.7.2 Regenerallon Process Instrumentdion

,

Recommenda_ tion. The regeneration system for the condensate polisher resin
should have adequate instrumentation to contml and monitor the resin ;
regeneration.
i
!

4-20

I
- _ - _ . _ . - . . _ _,_ _ _.._ _ _. _ _ . _ . . . _ , _ . _
_-
. - - _ - _ _ - _ - _ _ _ _ _ _ _ _ _ _ _ .

insillkation. The minimum instrumentation recommended for the regeneration '

system is listed in Table 4-2. .

1) Water Suppjy - The supply water (usually condensate) used for resin transfer,
backwashing, regeneration and rinsing must be controlled at a constant pressure to
ensure constant flowrates. The pressure controller should be capable of maintaining
water pressure at a constant value below the regeneration system design pressure ;
(generally about 100 paig).
t
,

'
Operators should be able to check system pressures at all times. Standard corrosion '
resistant dial type gauges on each vessel should be sufficient.
4

2) Enin Transfer - Hydraulle transfers are used to move resin from one vessel to
another. Operators should be able to check transfer Lquid Dows and pressure during ;

the transfer. The uansfer piping also should have sight glasses for visual
observation of resin Dow.

3) Air Scrub - Corrosion products removed from condens-te during the operating
'
. cycle tend to cover the resin beads with a more or less adherent layer. This layer
generally is removed during the regeneration process by compressed air agitation of
the resin in one or more of the regeneration vessels. Air pressure and Gow must be
properly adjusted and monitored during the scouring process to completely loo 3en :
resin surface deposits.

4) Backwashing - Upflow of water fluidizes the resin bed, and removes the loosened
corrosion products and resin fines through the top of the vessel. Proper
backwashing involves expansion of the bed, so each resin particle is in motion.
During hydraulic separation of resins in the cation vessel, sufficient bed expansion
must be maintained to allow the lighter anion resin to migrate to the top of the bed
and the heavier cation to the bottom.

5) Temperature has a pronounced effect on hydraulics through its effect on water y

viscosity. This factor is important especially during the backwash phase because
,
expansion' characteristics of the bed will vary whh temperature changes (Figure 4-9).
Consequently, the operator must be aware of backwash water temperature at all
times and adjust the backwash flow accordingly.
,

6) Air Mixing - After the separated resins are regenerated, they are mixed before
transfer to the polisher vessels. Mixing is accomplished by injecting air into the
bottom of the resin bed, which is covered with water to the top of the resin.
Sufficient agitation of the bed to homogeneously mix the anion and cation resins is
accomplished by control of air pressure and now. Some water may be required with
1 the air at the end of the mix period.

4-21

. . . . - - . - -. . . - _-
.- - - . _ - - . - - - . -
 ~ ,

Table 4-2

DEEP BED REGENERATION SYSTEM INSTRUMENTATION AND SAMPLING RECOMMENDATIONS

^
Parameter
System Measurement Pres s'u're''~felEpe ra t ure Flow Level Conductivity Sample

Regeneration system '

water supply XIC

Cation, anion, and .

. mix vessels XI

Resin transfer sluice

' water XI XI

Air scrub (cation.and

anion vessels) XI XI

Backwash and' separation

water rupply XI 41

Air. mix in mix vessel XI XI

Regenerated cation and

anion resin G

~ Acid dilution wate.' XI

Caustic' dilution water XIC XI

Acid and caustic

-storaga tanks XI

Diluted. acid and caustic XI G

,
~ Vessel ef fluent rinse water XI
9

.
-
.

X = Instrument-
21 = Indicator.
'C = Controller-
G = Grab-sample' capability

4-22

-, .x.-,_.._;..._..-____ ._ _ .... _ ~. _ _ - . . . . _ . . - - - _ . _ _ _
 7) Regenerated Resin Sample - Regenerated resins must be sampled periodically
and analyzed to determine resin condition, the extent of regeneration and
separation efficiency. Provision for sampling the separated regenerated resins in the
cation and anion vessels are needed. Resin samples can be taken from a transfer
line or the cation and anion vessel resin removal penetrations previously
recommended.

8) Dilution Water - The desired regenerant chemical concentration normally is

*
obtained by mixing a known flow of concentrated regenerant from a positive
displacement pump with dilution water. Operators must be able to check dilution
*
water flows and purity at all times. In addition, caustic dilution water generally is
heated to 95' to 120'F (35' to 50'C) for optimum silica removal. Temperature must
be monitored and controlled carefully; low temperatures yleid poor silica clution
(11q), and high temperature will cause anion resin degradation (4).

9) Regenerant Level - Resin contaminant elution dt. ring regeneration varies with
regenerant level (weight of pure regenerant per unit volume of resin). Average
regenerant level can be determined by recording the concentrated acid and caustic
storage tank levels before and after each regeneration. Volume per stroke, rpm, and
operating time of the positive displacement regenerant transfer pumps can serve as
a crosscheck.

10) Regenerant Concentrattom- Operators should be able to check regenerant

concentration at all times. Conductivity of the diluted regenerant can be related to
concentration. Also grab sample capability should be provided for periodically
checking regenerant concentrations by titration.

11) Rinse Water Conductivity - Rinse water effluent conductivity for the cation
resin rinse, anion resin rinse and mixed bed rinse are monitored to determine when
- the resin _has been rinsed sufficiently.

.'

4-23
 i i I i i

10"C 25"C 38"C 50 C

100 -
j j j j
-

/ / / /
/ / / /
/ / / / 10*C
! / / !
80 |
/ j'
-
'

| / zs,c
|
I /
/ / !|/ 38'C '/
60 -. I
/ /
/
/ / 50" -

e
I
I ,j / / /

.fi j
/
/ /
$
a
I / || /
-
i/ //
-
] 40 I/ //
Il '
|/
II /,|,/
//
'## , ^ato" "*da
20 -*l f
/ - - - - - - - - - -

/ // Cation 4tesin

0 l l I I I

2.5 5.0 7.5 10 12.5 15.0

Nckwash Rowrate, gpm/ft'
.

Figure 4-9. Typical Condensate Polisher Resin lled F2pansion

as a Function of Backwash Water Temperature and Flowrate ,

4-24
 _

Section 5.0

DESIGN ClllTEltI A: POWDEllED ftESIN SYSTEMS

5.1 POLISilElt VESSEL

5.1.1 Inlet 110w 12151tilndets

EcMnmendation. Condensate inlet flow distributors must be designed to prevent

'
Dow im},ingement on the precoat; axial flow rates between the precoated septa
should be kept low by providing open channels in the center and around the
,
periphery of the vessel,

Jus _tification. Iligh Dow rates near the precoat can wash the resin off the septa.
Ulssolved impurities then would leak through the septum and the exposed area
could become fouled with corrosion products. Fouled septa cannot be properly
precoated during precoat operations. Condensate normally enters the bottom of the
vessel and must flow up past the lower ends of the precoated septa. Precoat loss
problems generally are manifested at the bottom end of the septa where high flow
rates are necessary to supply water to the upper part of the filter area. Turbulence or
jets may occur because of poor inlet flow distribution. Particular attention should be
paid to inlet distributor design and to the availability of sufficient cross sectional
open areac to prevent high inlet flow along the axis of the septa.

5.1.2 Srphunlles.lga

Recommendation. Septum design must prevent precoat resin leakage from the
polisher during transient and normal operation.

Iustification. Leakage of resin frorn the polisher will result in resin input to the
steam generator. Thermal decomposition of the resin will contribute to the
generation of acid sulfates in the steam generator, which in turn :ontribute to a
variety of steam generator corrosion mechanisms. Septum design can be wire
mesh, fiber wound, or wedge wire.
.

5.1.3 Air and Water Supply

. Recommendation. System piping should supply both air and water in the reverse
direction through the filter elements to remove the precoat.

Justificallo.n. Insufficient cleaning of filter septa during the backwash cycle leads to
shortening of the run length and of the filter element life. If all the powdered resin
and filtered particulates are not removed during the backwash operation, pressure
drop across the septa will be higher than normal during the next cycle. The higher
initial pressure drop will decrease run len;,th. As resin and corrosion products
| become imbedded, the septa fouling increases.
!
1

5-1

- .-
- . . - . . . . . . - -
 _________ . . _ _ _ _ _ . _ _ .
_ _ __ _ __ _ ,

5.1.4 SJghLGLuses

Ecconunendallon. Sight glasses should be installed at the lower and upper ends of
the septa.

Jusilucation. The ability to see the filter elements and the precoat condition during
all phases of operation will allow identification of precoat problems before serious j
septa fouling. Early identification of poor precoats or washoff of precoats during . I
'
operation can permit operational changes which lengthen septa life and improve
polisher performance. Cracking of the precoat sometimes allows leakage of
dissolved solids and fouling of the septa themselves. Timely replacement of a i

cracked precoat will improve effluent quality. Consideration should be given to I

placing 3 sight glasses at each elevation (~120 degrees apart).

5.2 PRECOAT SYSTEM i

5.2.1 Precoat Mixing Sysicm |

Eccanunendalinn The precoat mixing system should be design to mix the resin ,

'
with slurry, using demineralized water or condensate as the makeup, and deliver
the slurry to the service vessel without contamination.

Justificatio.n. Preparation of the powdered resin slurry is an extremely important

part of the process. The mixing tank must be sized to contain the nnximum dosage
for a polisher vessel. A covered tank with small doors for e- mon of resin will
help minimize the contamination of the precoat mixture. Exposure of the slurry to
air should be rninimized to prevent exhausting the anion resin to dissolved carbon
dioxide.

5.2.2 PrecoaLPurg

Recommendation. Precoat pump capacity must be designed to ensure uniform

distribution of precoat on the septa and seal design must oc suitable for pumping
abrasive resin slurries.

Jus 11fication. Uniform precoats are a necessity to prevent contaminant leakage,

which shortens service runs. Velocity during the precoating operation is an
important factor in obtaining a good precoat. Decreasing the inlet slurry
concentration to the service vessel and correspondingly increasing the total precoat
time can lead to polisher performance improvements.

5.2.3 liolding.Ptunns

Recommendation. The holding pumps should be designed to provide sufficient

flow to retain the resin precoat on the septa.

5-2

-_ __ - ~_ _ __ __ _ _ .. _ _ _--
 - . - - --.

Iustificalion. The precoat will not remain on the septa unless there is a sufficient
flow (0.5 gpm/sq. ft.) through the resin causing sufficient pressure drop to hold it in
place. After being precoated, a polisher veswl normally is held in standby until
needed. The holding pump recirculates water 'hrough the septa during standby to
keep the precoat in place.

5.2.4 Rec!n Strainers

'
Eccommendation. Resin strainers should be casigned to withstand differential .

pressures equal to the total system pressure drop and such that routine maintenance
,
can be performed without significant out-of service time.

Iustifica11on. Similar to the situation of resin traps in deep bed demineralizer

systems, resin strainers are design to prevent catastrophic ingress of resin to the
steam generator in the event of an element failure. The strainer will require
periodic maintenance and inspection and, hence, the recommendation for system
design that incorporates this periodic maintenance conce n.

5.2.5 Resin Fines Filters

Recommendation. Resin fines filters,if desired in the system design, should be

compatible with system pressure drop concerns.

Justification. To date there is little operational experience with resin fines filters. ,

There is significant industry concern over the ability of condensate polishers to be

operated full-flow, full time with steam generator degradation due to sulfate (resin
throw).

5.3 INSTRUMENTATION

5.3.1 Precoat System Process Instntmentation

'

Recommendation. The resin precoat system should be designed with adequate

. instrumentation and grab sampling connections to properly monitor the system
performance.

. Tustification. Recon; mended minimum instrumentation and sampling capability

for the powdered resin precoat system are given in Table 5-1.

| 1) Backwash - Backwashing the filter elements to remove the exhausted powdered

resin and filtered particulates is one of the most critical operations. Capability for
'

the operator to monitor water and air pressures and flowrates to ensure they meet
operating specifications is essential.

5-3
|
|

~~ r .-.
e n._ . . .._._,, , ,, ,, .. . _ _ . _
 Table 5-1

POWDERED RESIN PREC0AT SYSTEM INSTRUMENTATION AND SAMPLES

Parameter
System Measurement TTe~ssure Flow Sampli

Backwash water XI XI
.

Backwash air XI XI*

Precoat pump discharge XI G -

Precoat mix tank G

Holding pump- XIS G

..

:
X = Instrument
! = Indicator
15 = Switch
G = Grab sample capability

* Note; Air flow measurement not needed for systems using Graver " Air Surge
Backwash Method"

(.-

54

. _
.- _ _ , . . _ _ ., _ _ _ _,_.- _ _ .. _ ... _ _ _ . _... _ .. _ ._ -
--_.;_.._..
 i

2) Precoat Pa.p Pressure - During the precoat procedure, precoat pump discharge :

pressure shomd be essentially the same for every precoat. Abnormal pump i

discharge pressure indicates a problem with the pump or some other part of the
precoat system.

3) Precoat Mix Samph- A sample of @ .asin slurry should be tested to verify that '

settling characteristics and clump size are consistent with manufacturer's

,
recommendations before precoating a polisher vessel. Samples also can be taken
from the precoat pump discharge during the precoating operation.
:
'

, 4) Holdine Pump - The holding pump must maintain the polisher vessel filter
j
element flow sufficiently high to keep the precoat on the elements. Operators
should be able to check the flow at all times; a low flow switch should activate an ;
!
alarm so that a vessel will not be put ,r ' vice if the resin precoat has been _
- damaged from a low flow condition. When resin leakage is suspected, holding
.

pump discharge samples can reveal resin fines penetration of the septa. -t

*
,

.* _
|
1

*.

5-5-
i

s_. - . . . ,, _ ~ _ , - . , _ .
-

. . . . . . . , , 5
 _ ..

Section 6.0

OPERATING AND MANAGEMENT RECOMMENDATIONS

6.1 MANAGEMENT OF ".'ONDENSATE POLISilERS

6.1.1 ManasemenLSitppntt

'
Re.cmuntendation. Management should clearly support operation of the polisher
system to achieve the water chemistry recommendations of Reference 11.

Judincadan. In order for condensate demineralizers to accomplish their mission of

improving the water quality to the steam generators, they must be operated within a
clear set of specifications with specific actions taken when effluent quality is outside
such specifications. It must be understood clearly at alllevels of management that
the required actions should take precedence over continued operation at out-of-
specification conditions if the long term integrity of the steam generators is to be
maintained.

6.1.2 .Canunitment to Resources

Rc.comntendatinn. Management must commit the necessary resources to provide

proper traintag for operators and maintenance personnel.

harificatim1.11is important to note that the engineering, design, and automation of

condensate polisher systems do not ensure proper or optimum results. No
sophisticated system can live up to expectations without proper training of
personnd condensate polishers are no exception. Overseas utilities generally c0cct
the most highly qutdified personnel to operate demineralizer plants, and no
amount of natomation is considered an adequate substitute for close and constant
monitoring by qualified personnel (12).

An operator cannot adequately follow condensate polisher system operation

without reliable, correctly calibrated instruments. Improper operation can cause
. serious chemistry deg!udation of the entire secondary cycle. Recovery of a
recirculating-type steam generator from resulting chemistry upsets takes
considerably longer that does the rest of the secondary cycle.
.

6.1.3 Maintenance Program

Recommendction. Management should ensure that resources are available to

properly maintain the condensate polisher system.

6-1

. _ _ _ _ _ _ _ _ _ _ _ - _ _ _ - _ _ _ _ _
 __ - _ . .
_ _ ..__._ _ _ . _ . - _ ._ . _ _ _ . _ . _ . _ _ -

Jusilficallon. Without adequate maintenance, the condensate polisher system will

be unable to meet its design objectives. In reality, an improperly maintained system
can be far more detrimental to steam generator integrity and reliability than the
condensate it was designed to purify. Appendix E details a recommended j
maintenance program. '

!
!

6-2

-- _ . .-..

e4,-,,-.,n.._e--. ,,.,..--.,y ,w., e

-

< ,._m,i . .-, ., ,mw, y, , * +---- - , < ~- r r:. , - - - . . . ,w- ,m -w1,w.-

| \

Section 7.0

OPERATING CRITElllA: DEEP llED POLISilER SYSTEMS

7.1 Ienninadun niSenite_lbm

Reconunendallon. The pclisher vessel service run should be terminated when the
vessel differential pressure increases to 45 psi, or when tho ammonia or sodium
starts to break through the bed.
*
,

Jutufsation. With 45 psi differential pressure across the process vessel and 4 to 10
"
psi across the resin strainer the polisher system differential would be limited to 55
psi. Polisher effluent quahty must be sufficient to meet PWR Secondary Water
Chemistry Guidelines (H). Polished condensate dissolved solids concentrations
which allow maintenance of the guidelines depends on type of steam generator
(once-through or recirculating), steam generator blowdown rate and ratio of
condensate now to total feedwater flow.

Polisher service cycle .ermination at ammonia breakthrough is recommended,

because a demineralizer generally will not maintain the sodium and chloride
concentrations at the necessary levels when operated through the transition from
hydrogen to ammonium form resin.

For a PWR operating with ammonia pII control at 9.0, cation to anion volume ratio
2
of one, a flow rate of 50 gpm/sq. f t (2040 liters /m -min) and a 3 ft (0.9-meter) deep
bed, the cz. tion resin will be exhausted completely to ammonia in approximately 12
to 16 days depending on the extent of regeneration and on total cation resin capacity.
Time to ammonia exhaustion for a PWR operating at pil 9.4 would be 3 to 4 days. A
variety of possible techniques are available to increase hydrogen cycle operating
time:

1) Increase fraction of cation in mixed bed.

2) Increase bed depth.

3) Reduce flow rate.

*
4) Install a cation bed upstream of the mixod bed.

Increasing the cation-to-anion volume ratio to higher that two can result in a mixed
bed with insufficient capacity to handle silica and carbonate from turbine air
inleakage. As anion resin kinetics degrade with usage, anion leakage can become a
problem even with 2 to 1 volume ratio beds (fi).

7-1

|
|
_ - - - - _ - _-___ _ _ - _ _ _ ______-_____ _______ -

Significant increases in bed depth would cause a corresponding higher bed pressure
drop. However, the combination of deeper beds and lower flows could be used to
maintain pressure drop constant. The longer contact times resulting from lower
flow rate and deeper beds vould improve dissolved solids removal (See Appendix
2
B) However, flow rate much below 40 gpm/ft may impact crud removal capability.

A cation bed to remove ammonium ion in front of a mixed bed would provide
maximum mixed bed cycle time because only condensate impurities reach the
mixed bed. Continuous operation near pH 7 of a 2 to 3 volume ratio hd with
hydrogen /hvdroxide form ref.ns would produce high effluent water quality. The
cation bed regeneration frequency would vary from a few dayr to over one week,
depending on polisher inlet ammonia concentration. Regeneration of the cation bed .

requires no separation and can be performed in a few hours. The more difficult
regeneration of the mixed beds would be infrequent (< once per month) because of
the mixed bed inlet low dissolved solids concentration.

7.2 Balancing of EmY

Recommendalqn. Condenrate flow through all service vessels should be e

per!odically equalized (balanced).

,

]nsufication Without flow balancing, a vessel which has been in service collecting
suspended solids will have a higher pressure drop and operate at lower flow than a
vessel recently put into service. Since the resin removal efficiency for dissolved
solids decreases with increasing flow rate, the efficiency of the newly regenerated
bed, wh!.ch should produce the highest quality water, suffers. In addition, when bed
flow rates are not balanced, flow surges that result from exchanging polishers are
increased, which promotes leakq? of suspended solids.

7.3 liphlPoint inlegeneration Prouss

Eccommendation. Hold points in the automatic regeneration process should be

implemented to allow visual inspection.

Tustificallar Visual verification of the following items is important in assuring

quality regHurations:

1) Complete transfer when resin is hydraulically moved from vessel to vessel.

2) Correct backwash water temperature, flow rate, and bed expansion.

3) Maintenance of clear and level interface between cation and anion layers after
nydraulic classification.

7-2

I
- -_ _ _ -
 .
.. - _ - _ - - - - - - - - - - - . . _ - - - -

h Conect volumes of cation and anion resin, based on regeneration vessel resin
levels.

Automation of the regeneration sequence is not an adequate substitute for close and ,

. constant monitoring during each step of the regerieration. Sight glasses were
recommended just above the underdrain on all polisher and regeneration vessels.
-To prevent problems such as resin charge volume changes, resin contamination
and impurity threw associat.ed with incomplete resin transfers, these sight glasses
,
are to be used to visually check resin transfers. When resin is left behind, corrective
action should be carried out before proceeding to the next procedural riep.

, Backwash W.cr temperature has a significant infb' .m on bed expansion for a

given flow rate (Figure 4-9) (JD). For example, at ..EF ;0 C) a flow of
- approximately 5.7 gpm/ft2 (230 lik.,/" min) t. pired for 100% bed expansion of
a one-to-one volume mix of typical condensate polisher cation and anion resin, but
- the same flow at 77 F (25 C) would give 140% bed expansion. Either serious resin
loss or insufficient bed expansion may result if backwash water temperature and
flow are not controlled conearrently. With sight glasses at the top of the cation
vessel,in which the' mixed resin normally is backwashed and separated, the
appropriate backwash flow rate can be visually verified.

- After the mixed resins have been classified hydraulically and allowed to settle, the
resin interface should be checked before proceeding to the anion transfer step.
When separated properly, a distinct interface between the two resin layers should be
visible, and the interface should be level around the vessel periphery as viewed
through the vessel sight glassee. A non-horizontal interface indicates poor
backwash flow distribution possibly caused by problems with the vessc! underdrains
or upper collector. The interface design height should aarked on the sight
glasses and the resin interface 1 cel should be maintained within +1 in of the proper
level (1-inch in a normal 5.5 to 8 ft, diamtter vessel represents a resin volume of 2.8
- to 4.2 cu. ftJ. Addition or removal of cation resin is required when the interface is
not within these limits.

- 7.4 AitSrInbYtug
4

Recommendation. The exhausted mixed-bed resins should be air scrubbed

'
approximately 10 minutes at an air flow of 6.5 to 11.5 scim/ft2 (2 - 2.5 standard cubic
- meters per square meter) of vessel cross sectional area.

Option. Instead of air scruu ag, resins can be cleaned with ultrasonic resin cleaner
-(la) according to the vendor's recommended operating procedures. ;

Tustificatton.- Condensate suspended solids are primarily corrosion products.

Corrosion products (crud) removed by the polisher resins tend to cover the resin
beads with an adherent layer. This layer must be removed completely to prevent

I
7-3 ;

-.
 _ _ . _ - _ _ _ _ . . _ _ . . _ . - . _ _ _- _ _ _ _ .

~ degradation of the resin kinetic performance as well as loss of the resin surface
properties that are responsible for corrosion product removal. Most condensate
polisher system vendors, therefore, employ air agitation of the resin in one or more
of the regeneration vessels to loosen adherent corrosion product deposits. The
loosened deposits are flushed out of the resin with backwash water.

General Electric developed the ultrasonic resin cleaner to effectively remove '
.

corrosion product particles from ion exchange resina (Figure 7-1). The exhausted
resins are put through the cleaner after transfer to the cation vessel. Ultrasonic
energy loosens the particulates which are flushed out the top of the cleaner along
with resin fines. -Ultrasonic cleaning generally wu! dean the resin as well or better
than air scrubbing. However, if improper operation of the cleaner allows resin to '

contact the side walls, the resin can be pulverized.

7.5 Backwash and Settling

Recommendation. The backwash and settling procedure, arijusted to give the

maximum bed expansion allowed by the cation vessel freeboard, should be
performed twice.

Instification. The raixed resins are backwashed in the cation vessel to remove the
loosened crud, sepa. ate.the resins and remove resin fines. Acjustment of the
backwash flowrate to give the maximum bed expansion allowed by the cation vessel
freeboard is recommended (preferably 100%).

Although typical backwash rates are 2.5 to 5 gpm/ft2 (100 to 200 liters /m2 -min), the
equipment and resin manufacturers' recommendations should be followed. The
backwash flow should be maintained for'15 to 30 minutes and then the bed allowed
to settle by gravity. It is recommended that this backwash and settling proce..ure be
repeated twice. I' the interface is not within +1 in of the design level, the backwash
should be repeated. Cation resin addition or rr.noval is required if the interface is
| still not within limits.

Resin crud and fines removal and separation efficiency increase with bed expansion.
,
Sufficient freeboard to allow 100% bed expansion gives a reasonable compromise -

p between vessel cost and efficiency. Repeating the backwash and settling procedure
|- improves separation and assures complete removal of loose cred. Backwashing
| should not be discontinued when crud still is visible in the vessel effluent water. *

Crud in the backwash can be evaluated either by viewing the vessel effluent water
through a glass in the discharge line or sampling the water. Loose crud left in the
resin is likely to end up in the steam generators. To minimize contamination by
regenerant chemicals, it is important to maintain the interface within the specified
--limi,ts.
|

7-4
 -

Float
Switch
Vent \
't
'
b _

T i _
] +--- Dirty Ret.in Inlet
Ill!Illll!!!ll!1T!!IliI!!!
. lilllllllillllll!!!Illjlif
To Waste IIIIIII!I!IIIIII!IIIIIII
.
R$$e'ry
/

l' -

5
Ultrasonic
Transducers

!
Renin /
Cleaner d L /
'Jank

'N %

If

l 1 -

Backwash s #( ( ) 4 -- Dackwash
Manifold _ _ _ _ _
. High Resin level
31ij _ii,ijg Trip Probes
-"
Conductivity
Level Probes _
'
*

i.
'~I .

1
#
To Hold Tank _ _ _ , y
+-- Water Su}. ply
_

4... <

Figure 7-1. Ultrasonic Resin Cleaner

75
- -- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

7.6 Anion _ Resin Transfer

Reconunensla11on. The anion resin transfer process should be conducted with

safeguards to insure minimum amounts of cation resin is carried over.

Insnucation. Cation resin carried through the anion regeneration process causes all
exchange sites to be in the sodium form and will lead to early bed exhaustion.

It is recommended that the cation / anion interface design level be located

approximately 3 in. (8 cm) below the cation vessel anion transfer collector. The
following two-step transfer should be used:

1) Transfer bulk of anion resiv to anion vessel with sluice water entering the
top of the cation vessel.

2) Backwash resin in cation vessel again for 15 minutes to obtain maximum

permissible bed expansion. Flows of up to 14.5 or 17 gpm/ft2 (600 or 700
,
liters /m'-min) may be possible.

3) Allow bed to gravity settle.

4) Transfer remainder of anion resin by applying sufficient flow up through the

cation resin to maintain a level interface and lift the resin interface to the
level of the anion trcnsfer collector drop-legs (flow on the order of 2 to 5
2 2
gpm/ft or 80 to 200 liter /m -min). Sluice water is supplied from the top of
cation vessel as needed.

5) If more than 1/2 in of anion is observed in the cation vessel after settling, -

repeat step 3.

6) Visually check anion vessel for evidence of cation from the last transfe . U ~

cation is present, the interface was not contrc.ied F the proper level or there
are resin density problems.

The first transfer of the main body of the anion resin, while the interface is 2 to 4 in.
(5 to 10 cm) below the transfer collector, ensures removal of anion resin only. The
vigorous backwash before the second transfer improves separation of the large
anion beads from the cation layer and washes cation fines out the top of the vessel.
During the second transfer, the upflow fluidizes the cation resin and raises the
interface to the anion transfer collector level. Fluidizing the cation maintains a
level interface during the transfer giving optimum s.,2 ration. After allowing the
cation to settle, the separation should be checked to verify that fluidized avion resin
didn't remain in the cation vessel during the final transfer.

7-6

_ _ _ _ _ _ _ _ . _ _ _ _ _ _ _ _ _ _ _ _ _ _ . _ . _ _ _ _ . _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ . _ _ _ . _ _ _ _ . . _ _ _ . _ _ _ _ _ _ . _ . _ _ _ _ . _ _ _ _ _ . _ _ _ _ . _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ . _ _ _ _ _ _ _ _ _ _ . _ _ . _ _ _ _ _ _ _ _ . _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _
 . . - . . .-. -

A well designed carefully operated and well maintained regeneration system should
provide sufficiently good resin separations with the recommended conventional-
- type separation to maintain the required effluent levels at belmv 1 ppb. Modified
separation and regeneration procedures may be required for poorly designed and
operated polisher systems. Use of one or more of the modified procedures given in
Appendix C may improve system performance.

7.7 Concentration of Regenerants

~

. Recommendation. During a conventional regeneration, sulfuric acid

concentrations of 6 to 10% by weight and sodium hydroxide, generally " rayon
,
quality" or better, concentrations of 6 to 8% by weight are recommended.

,lustinc,h. Regeneration efficiency increases with increasing regenerant

concentration as is indicated for regeneration of ammonium form cation resin and
chloride form anion resin (Figure 7-2 and Table 7-1, respectivaly). However, resin
degradation as a result of osmotic shock also increases with regenerant
concentration. The suggested concentrations are a reascnable compromise between
efficiency and resin degradation.

Sodium chloride in caustic will contaminate the anion resin during regeneration
(14). Thus, low chloride caustic, such as rayon grade (<0.3% Nacl) should be used.
Caustic reclaim may be counter productive, particularly when the polishers have
removed chloride from condensate during the service cycle.

7.8 Quality of Regenerants -

Recommendation. Regenerant parameters should meet or exceed those listed in the

following table:

3
Loading - 12lb/ft (200g/1)-
Contact Time - 30 minutes minimum
*
Injection Time - per manufacturer's recommendation

,
Temperature - 95-120 F (35-50 C)(caustic only)

TUSTIFICATION:
|
Figure 7-2 shows that approximately 80% of the ammonium form gel cation resin
will be converted to hydrogen form at the minimum suggested regenerant level.

7-7
 100
| I I I I l | |

80 -
-

e 60 _
_
cf
'@ te
oc
5
y .c
os .2
E
-$ 4 9
-
-

2
E
<
!

20 -

37 __

0 l' | | | | , ,
i

0 5 10 15 20 25 30 35 40
Sulfuric Acid Regenerant level,Ib 98% HM/ft' Resin

Figure 7-2. Elution of Ammonium Ion from 8% DVB Cation Resin

. . - -
 _ _ . . .

Table 7-1
CHLORIDE REMOVAL WITH CAUSTIC SODA

Sodium Hydroxide Concentration *

4% 8% 16% 20%

I
Anion Exchange Resin Percent Chloride Removal

Porous Gel 57 70 84 96
-
Macroporous 64 72 83 97

* Resin exhau-ted to 0.18 meq Cl /ml resin and regenerated with

15 lb NaOH/ft3 (240 g/ liter)

..

.,
 _. . _ - - . _ _ _ . _ _ _ . . _ _ _. . ._ . _ _

- Approximately 80% of the sodium in the exhausted cation resin also would be
3
removed by 12 lb/ft sulfuric acid (J11) The difficulty of using type-1 strong bam
anion resin for condensate polishing is demonstrated in Figure 7-3 01). At a
3
regeneration level of 12 lb/ft sodium hydroxide, chloride form macroporous resin
is approximately 55% regenerated to hydroxide, and sulfate form resin is about 75%
converted. For gel-type anion resin, this regenerant level would give somewhat
higher hydroxide capacity. However, even for gel type resin the suggested
regenerant level will not be sufficient for regenerating anion resin after a condenser
leak, if the resin is operated in the ammonia cycle. Regenerant caustic temperatures
in the 95 to 120'F range are required to remove polymerized silica from the anion
resin.

The following of manufacturer's suggested application rates (generally 0.25 to 0.5

3
gpm/ft of resin) will ensure sufficient contact time, provided tha; good regenerant
distribution is achieved.- Proper regenerant distributions should be verified visually
at the beginning of a regeneration.

7.9 Einsing

Recommendatinn. The regenerated resins first should be rinsed slowly to displace

the regenerant and then rinsed for 10 minutes at 4 to 8 gpm/ft2 (160 to 320 liters /m2-
min).

Iustification. This rinse removes the acid and caustic from the bed void volume
, and reduces the concentration with the resin beads.

7.10 Second Air Scrub Technlaue

U

Recommendation. Following the regeneration and rinse cycles, the resin should
again be air scrubbed for 10 minutes and backwashed.

Justification. The air scrub after regeneration removes additional crud from the
resin; the backwash removes this debris frc.n the cation and anion vessels ensuring .

the cleanest possiole resins for the next service cycle. In addition, the process aids in
rinsing the resins. Rinsing is accomplished by good resin / water contact during the
-scrub and backwash operations. Also the mixed and settled bed will provide better
flow distribution during the completion of the cation and anion resin rinses.

7-10

_ ._-
f

,
100 -

e
a
80 - 9-

] 60 -
,

b
e
x e
2 -
8 40
b
E SO7(orm
20
9 C1' form

0 | | ;

15 30 45

Sodium Hydroxide Regenerant Level,1b NaOH/ft'

.

Figure 7-3. Effect of NaOH Regenerant Level en Regeneration

Efficiency of Chloride and Sulfate form Duolite A161 Resin
,

|
|

7-11
 7.11 Mixed Resin Rinse

Recommendation. The cation and anion resin should be rinsed at 4 to 8 gpm/ft2

(160 to 320 liters /m2-min) to a 30 uS/cm end point for the cation resin and 10 uS/an
fe" the anion resin.

Justification. It is important to rinse residual sulfate from the cation resin and
sodium from the anion resin before the resins are transferred to the storage vessel.
An excellent separation will not prevent chemical contamination of the resins if the
individual resins are not properly rinsed. Total rinse water volumes should be in
3 3
the range of 30 to 60 gal /ft of resin (4000 to 8000 liters /m ) with the larger volumes .

being required as the resin ages.

7.12 VisualInspection

Recommendation. A visual irapection should be performed after and to insure

complete resin transfer.

Justificatinn. Complete resin transfers are necessary is assuring future success in

_

regeneration of other resin charges.

The flow of water through the vessel underdrains moves resin to the transfer pipe
and allows resin to be removed from the vessel. If resin remains in the
regeneration vessels after the transfer, partial filling of the vessel, air mixing and
draining of the vessel should help rentove the remaining resin. The following
method has been shown to be effective:

Drain mix / storage vessel completely, and drain cation and anion vessels water level
to the top of the resin. Pressurize vessel with air and supply sluice water to the
bottom of the anion vessel until all anion resin is transferred to the mix / storage
vessel. Transfer cation resin to mix / storage vessel using same procedure. The -
cation and anion vessels should be visually checked for completeness of transfer.

7.13 Resin Mixhig -

Recommendation. The resins should be mixed by draining the water level to the
top of the resin bed and injecting air into the bottom of the vessel at 6 to 12 scfm/ft2 -

of vessel area (2 to'3.5 std m3/m2-min) for 5 to 10 minutes.

.

Justification. Air bubbling through the resin-water mixture vigorously agitates the
bed to thoroughly mix the anion and cation resins.

7-12
 _ . -- . - -. -

7.14 Final Rinse

Recommendation. The final rinse of the regenerated resin should involve a slow
- fill of the mix / storage vessel and downflow rinse at 4 to 8 gpm/ft2 (200 to 320
liters /m2-min) to a conductivity end point of 0.3 uS/cm.

Iustification. Mixed bed rins_c time willincrease with age of the resins. Resin
_

kinetics degrade as the resins become fouled with organic matter and corrosion
products. Rinse time requirements to obtain 0.3 uS/cm conductivity often increases
with resin in service aging, particularly for fouled anion resin (2). The regenerated,
'
rinsed resin will remain in the mix and storage vessel until a condensate polisher
bed exhausts.

- 7-.15 Resin Transfer

Recommendation. The regenerated resin should be transferred to the polisher

vessel, carefully mixed, and prepared for service.

Jnstification. Although the resin transfer process should minimize resin separation
during the transfer, some separation of the cation and anion resin generally occurs.
To ensure a completely mixed bed, the resin is air mixed in the polisher vessel.
After the mix, the vessel is filled and remains in standby until it is needed to replace
an exhausted polisher. Impurity ions on the resins will be released to contaminate
the water phase in the idle vessel until equilibrium is reached between the two
phases. The contaminated water in the resin bed must be rinsed from the bed prior
to operation to prevent contaminant input to the steam generators. Rinse water
during the first five minutes is not recirculated to the condenser because of the high
contaminant concentration. After the water in the bed has been displaced,
recirculation to the condenser is started. The recirculation line must discharge to
the top of the condenser so that dissolved gases in the water are removed by the
condenser air removal section.

The most difficult ion to remove from the resin bed is sulfate, and the difficulty
. increases as the anion resin ages. Use of the high flow recirculation rinse provides a
means of minimizing sulfate contamination of the polhher effluent during the
service cycle. The high flow recirculation rinse also dislodges resin fines that may be
=, _ _ present at the bottom of the bed and collects them at the top. This minimizes fines
leakage during the service cycle. It would be beneficial to continuously recirculate
polishers while in the standby made.

i
'
..

7-13 ;

)
|
 . . _ _ _ . - _ . . . . _ . _ . - _ - _ _ _ _ _ _ _ _ . _ _ _ _ _ . _ _ - . - _ _ . . - . _ _ _

The following sequence of operations is suggested:

Drain the polisher vessel to receive resin and drain the mix / storage vessci
'
1)
until the water level is at the top of the bed.

2) Pressurize the mix / storage vessel with air. Introduce sluice water into the
- bottom of the vessel and transfer resin to the polisher vessel with the
polisher vessel drain open. .

%.
' \

7-14
:1
1

'
l - . - , , - - . _ . - , . . , _ _
-

. _ , _ _ _
 . -, .
. _ _

Section 8.0

OPERATING CRITERIA: POWDERED RESIN POI,ISliER SYSTEMS

8.1 Maximum Pressure Drop

Rcrommendation. A polisher vessel should be removed froni carvice when the

- pressure drop across the precoat approaches 25 psi or when the effluent water quality
,
is insufficient to meet the chemistry recommendations of Referer. , 11.

Instlucaibn. Powdered resin condensate polisher vendors generally recommend

,
continued operation for particulate removal up to polisher vessel clifferential
pressure of 25 to 50 psi. Operating the precoat to a differential pressure of about 25
psi will utilize much of the crud holding capacity, without creating backwash
problems Pressure drop across the filter increases rapidly above this loading (.11).
Vessel filter elements should be cleaned or replaced if the service cycle initial
pressure drop reaches 15 psi.

Maximum concentrations'of dissolved solids which will allow maintenance of

PWR Secondary Water Chemistry Guidelines depend on the type of steam generator
(once-through or recirculating), steam generator blowdown rate, and the ratio of
condensate flow to total feedwater flow.

It is unlikely that a powdered resin polisher system could maintain the required
'
concentrations for the recirculating steam generator system during condenser leaks,
unless the cooling water dissolved solids concentration was very low.

3.2 Balancing Flow Rate

Recommendation. The flow rate through all filter /demineralizers should be

periodically (and maintained) balanced.

Tustification. Without flow balancing, a vessel which has been in service collecting
. suspended solids will have a higher pressure drop and_ operate at lower flow than a
| . vessel recently put into service. Since the resin removal efficiency for dissolved
L solids decreases with increasing flow rate, the efficiency of the ncwly regenerated
bed, which should produce the nh; hest quality water, suffers. In addition, when bed
L .
flow rates are not balanced, flw prges that result from exchanging polishers are
increased, which leakage of suspended solids.
p
8.3 Backwash Flow Rates

Here mmendation. Backwash water flows for removal of precoat media should be
'
m the 0.5 to 1.5 gpm/ft2 (?.0 to 60 liters /m2-min) range for 10 to 15 minutes; air flow
rates of 0.1 to 1 scfm/ft2 (30 to 300 liter /m2-min) will be required.

8-1

~ - _ _ _ _ _ _ _ _ _ _ .
 - . - - . . - - - - -- - - - . - . . _ - - . , . - .

Jus 1111ntion. A critical step in obtaining a uniform precoat is proper removal of

'
resin and contaminants during the backwashing operation. Any obstruction of the
septum (bubble, crud, etc.) will result in an area void of resin after application of the
precoat. The void area allows not only leakage of contaminant but also fouling of
the filter element with particulate crud. High backwash flowrates are needed to
ensure crud removal from the entire element. The Graver " Air Surge Method"
uses short duration, high velocity bursts of air to drive backwash water through
localized sections of the septa. Areas where the resin or crud adheres to the filter
element will be bypassed at low backwash flowrates. Obstructed areas lead to ever
increasing filter element fouling.

8.4 Resin Loading

,

Recommendation. Filter element loadu mould be 0.2 to 0.3 lb dry resin per
square foot (1.0 to 1.5 kg/m2) for startup operation and 0.15 to 0.2 lb/ft2 for normal
operation.

II:stificition. Higher precoat loadings are used during startup operation to remove
dissolved solids which normally are of higher concentrations. The powdered resin
polishers primarily serve as suspended solids filters in normal operMion. Cation to-
anion resin dry weight ratio of 1:1 for startups and 2:1 for norm - an
commonly are used. The precoat material is a blend of commt available
powdered cation and anion resin and/or fiber material which c a be' varied to meet
plant operating conditions. Continued operation with condenser cooling water
inleakage is not recommended.

8.5 Preparation of Ilesin Sluny ,

Recommendation. The resin slurry should be carefuUy prepared in the mixing

tank.

Justification. Preparation of the powdered resin slurry plays an important part in

obtaining a good precoat. Powdered cation and anion resins when mixed with water
form a uniform cation-anion resin slurry which is bulky in nature and results in a -

high porosity precoat. A properly prepared slurry will have mixed resin particles
(clumps) about 0.34 to 0.65-cm diameter and will contain negligible resin fines. This
characteristic permits operation of the precoated filter elements at high area flow .

2
rate (4 gpm/ft ) and low pressure differential (1.5 to 25 psi) with 5 ery efficient
removal of suspended contauinants and reasonable removal of dissolved solids
from the condensate Resin fines in the precoat slurry or small clumped resin
particles will form a compacteci precoat with high vessel pressure drop. Resin fines
also may leak through the precoat causing septa fouling and steam generator resin
ingress. Excessively large resin clumps will form a nonuniform high porosity
precoat with poor characteristics for removal of suspended and dissolved solids.

8-2
|
 -. . . .

Since precoating with an improperly prepared slurry can lead to filter element
damage and contaminant leakage, slurry quality should be carefully checked prior to
application. It is essential that the resin slurry be prepared in the mixing tank as
follows:

1) Thoroughly clean the tank.

2) Fill tank with demineralized water of <120 P.

'

3) Start agitator and prepare resin slurry as quickly as possible (maximum of 30 .

minutes). Add the required anion rec.in and mix for five mlnutes. After
anion resir is mixed, slowly add required quantity of cation resin.

4) The slurry should be thoroughly mixed for a period of ten minutes after all
resin has been added.

5) Sample slurry while it is mixing in a one-liter graduate and allow to settle for
10 minutes. The settled resin should comprise about 55% of the original
volume and the liquid above the resin must be sufficiently clear that the
operator can easily see through the graduate.

6) Follow resin vendors' recommendations regarding addition of flocculating

agents.

8.6 Flow During Precoat Process

Essnemendation. The precoat flow should be 1 to 1.5 gpm/ft2 (40 to 60 liters /m2-
min) for precoating the process vessel septa.

Iustification. -The water velocity through the filter elaments needs to be sufficiently
high to uniformly distribute the resin on the filter elements and to compact the
precoat. It should be noted, however. that reducing the average resin concentration
-in the feed to the process vessel,i.e., extending the total precoat time, has been
observed to improve precoat characteristics. Two precoating techniques have been
p
.
used:
i

| 1) Discard precoat water after passing it through the service vessel; or

.
L

L 2) Circulate the precoat water through the service vessel and back to the precoat
i tank.

8-3
 .. . - - -- .. - . . - .. .

8.7 hiinhnunLIlme in Hold Mode

Eccommendalinn. The new precoat should be maintained in the " hold mode" for
two hours or longer.

htitificallan. Leakage of resin fines can occur, particularly for the wire mesh type
septa, when a newly precoated vessel is put into service. Maintaining the polisher
vessel in hold node for several hours can help reduce resinous material leakage ,

when the polisher is put into service (18).

8.8 Use of Body-Feed for Additional Capacity

Recommendatinn. Condenser leaks should be fixed rather than attempting to

bodyfeed resin into the filter /demineralizer to acquire more ion exchange capacity.

Justification. Band-Aid operations are never recommended. The source of the

condenser cooling water leakage should be identified and necessary repairs made.
Techniques are available to locate condenser tube leakage at rates at and below 0.0001
gpm (0.4 cc/ min) (19).

! -
,

|
8-4
 - - - - - - -- - . .- -- .- .-. - - . - . - ..

Section 9.0

REFERENCES

1. Emmett, J.R., " Condensate Polishing: A New Approach," presented at British

- Nuclear Energy Society, Bournemouth, England, October 1977.

2. Harries, R. R., and Ray, N. J., " Acid Leakage from Mixed Beds," Effluent and
Water Treatment Journal,18, pp. 487-495,1978.

3. Steam Generator Reference Book, Steam Generator Owners Group and the
Electric Power Research Institute, Palo Alto, California. May 1986.

4. Kuhne, G., "Special Characteristics of Ion Exchange Resins for Nuclear

Technology," VGB-Speisewassertagung, pp. 21-30, 1972.

5. Dionex Corporation, " Critical Pomts to Consider when Using Concentrator

Columns," Technical Note 8, January 1981,

6. Goodfellow, G. I., et al., " Factors Affecting the Limit of Detection of Sodium
Responsive Glass Electrodes," Analyst,101, pp. 848-853,1976.

7. Eckfeldt, E. L., and Proctor, W. E., " Low Level Sodium Ion Measurement with
Glass Electrodes," Analytical Chemistry,43, p. 332,1971.

=8. " Condensate Polishing at Plant Bowen", Steam Generator Owners Group,
Electric Power Research Institute.

9. 1982 Annual Book of ASTM Standards, Part 31,' Water, American Society for
Testing and Materiab,1982.

10. Dow Chemical Co., "Dowex Ion Exchange Engineering Manual, " T. D. Index
120.04 and 220.01.
.

11. "PWR Secondary Water Chemistry Guidelines," Rev.1, prepared oy the PWR
Secondary Water Chemistry Guidelines Committee, Steam Generator Owners
-
Group, Electric Power Research Institute, Palo Alto, California. June 1984.

11a. Osmun, R.,' and Wirth, L., Jr., " Silica Removal with Strong Base Resins,"
.
*

Industrial and Encineerine Chemistry. 43, p.1076, May 1951.

12. Strauss, S. D. et al., " Ion Exchange," Power,124, pp. S.1-S.16, September 1980.

13. General Electric Co., " Product Specification for the Ultrasonic Resin Cleaner,
Model 4," September 1979.

9-1

_- .- __ _ -__
 -. . - _ _ - - - . . . . - . - - . . . -. - .-. ~-

-14) McGarvey, F. X., et al., "Effect of Caustic Quu'.ity on the Performance of Strong
Ilase Anlon Exchangers," Proceedings International Water Conf.,42, pp. 297-
304,1981.

15. Emmett, J. R., and Grainger, P. M., " Ion Exchange Mechanism in Condensate
Polishing," Proceedings of the International Water Conference,40, pp. 81-88,
1979.

16. Wolf, J. J. and Abranis, I. M., " Operating Experience with Triobed in the
_ Production of Ultra Iligh Purity Water," Proceedings of the International ,
,

Water Conf.,40, pp. 263-267,1979. .

17; Levendusky, J. A., and Olejar, L., " Condensate Purification Applications of the
-

Powdex Process in High Pressure Utility Plant Cycle," Proc. American Power
Conf., 29,1967,

18. Eherts, R. F., " Operating ' Experience PWR/Precoat Filters at Calvert Cliffs -
_

Nuclear Power Plant," EPRI Corrosion Advisory Council-Condensate

Polishing Demineralizers Subcommittee, Phoenix, Arizona, December 1978.

19. " Condenser Inleakage Monitoring System Development", Steam Generator

Owners Group, Electric Power Research Institute, Palo Alto, California.
September 1982 (NP-2597).

'9

9-2

|
._
 _ _ - - .- - - . .

Section 10.0

CHECKLIST
(Number in parenthesis refers to number in chapter)

YES NO

DESIGN CRITERIA - DEEP BFD POLISHER SYSTEMS

*

1. The vessel influent water should be distributed _____ _____

over the entire area of the polisher vessel

such that uniform flow through the bed is provided
and the water flow does not fluidize the top
of the resin bed.
(4.1.1)

2. The polisher vessel underdrain design must _____ _____

provide uniform flow across the entire resin

bed, complete removal of exhausted resin for
regeneration, protection from resin plugging,
and sufficient support to withstand expected
weight and hydraulic forces.
(4.1.2)

3. Sight glasses should be installed just above _____ _ _ _ _

the bottom support plate, at the resin

interface (s), and at the top of the resin bed.
. (4.1.3) -

-4. A condensate polisher vessel recirculation pump _____ _____

o (Figure 2), capable of near-normal operating

flow rates should be installed.
(4.1.4)

.
5. The underdrain must be designed to provide _____ _____

uniform flow during the up-flow backwash

operation, and the down-flow regeneration and
rinse modes.
- (4.2.1)

..

+
10-1

L
 CHECKLIST

YES NO-
6. The vessei influent rinse water should be _____ - _____

distributed over and the backwash collected

from the entire area of the cation vessel to
provide uniform flow.
(4.2.2)
.

7. A sampling penetration should be installed for _____ _ _ _ _ _ .

sampling the inte.* face between the cation and ,

anion resins (or other resin interfaces).

-(4.2.3)-

8. The acid distributor laterals or nozzles should _____ _____

be designed for uniform acid distribution across

the resin surface.
- (4.2.4) -

9. The cation resin take-off should be de'8gned so' ___ _ _____

that complete removal of the cation resin from

the vessel is routinely possible.
(4.2.5)

L 10. Sight _ glasses should be ins.talled just above _____ _____

the bottom support platej at the resin interface (s),

at the top of the resin bed, and at the top of
the vessel.
(4.2.6);-

'll. The underdrain should be designed to provide _____ _____

; uniform flo.w during the regeneration and rinse

modes ~ and should permit complete removal of resin
during the resin transfer operation. -

(4.3.1) .

12. The vessel influent rinse water should be _____ _____

distributed over the entire area of the anion

vessel.to provide uniform flow.
(4.3.2)

||
[ 10-2

- - . . . ..
 - . . . - .

CH6CKLIST

YES NO

- 13. A penetration should be installed to permit _____ _____

the addition or removal of anion resin.

(4.3.3).

,
14. - The caustic distributor laterals or nozz'.es _____ _____

should be designed for uniform caustic

distribution across the resin surface.
. (4.3.4)

15. The anion r~in take-off should be designed _.____ _____

so that con., ete remeval of the anion resin

from the vessel is routinely possible.
(4.3.5)

16. Sight glasses should be installed just above _____ _____

the bottom support plata, at the top of the

resin bed, and at the top of the vessel.
(4.3.6)

17. _ The underdrain must be designed to provide ____ _____

uniform flow during the mixing and rinse modes.

(4.4.1)

18. The resin transfer take-off should be. designed ,_____ _ _ _ _ . _

so that complete removal of the resin from the

vessel is routinely possible.
(4.4.2)

19. Sight glasses should be installed just above _____ _____

the bottom support plate and at the top of

.
the resin bed.
(4.4.3)

- 20. . All system materials should be designed to _____ _____

be compatible with the various concentrations

and mixtures of regenerant chemicals.
(4.5.1)

10-3

. , . , _
-
- . _ _ - _ _ .
 ._ _ _ _ _ _ _ _ . __. -. _ _ _

- CHECKLIST

YES NO

21. Regenerant metering pumps should be positive _____ _____

displacement pumps with pulse dampeners.

(4.5.2)

22. Piping should be constructed of, or lined with, _ _ _ . . _ _____ .

an appropriate corrosion resistant material.

(4.6.1)

. 23. The sy, tem layout should be designed to provide _____ ._____

easy access to valves for maintenance or replacement.

(4.6.2)-

24. If resin traps are designed in the polisher _____ _ _ _ _ . .

effluent lines, che traps should be designed to

be readily backwashed, capable of taking a large
pressure drop when clogged, and located for easy
inspection and cleaning.
(4.6.3)
.

25. -Resin fines filters,if desired in the system _____ _____

design,-should be compatible with system pressure

drop concerns
(4.6.4)

26. The condensate polisher system should have _____ _____

-adequate process and chemistry instrumentation

to keep plant personnel apprised of system performance.
(4.7.1)

27. The regeneration system for the condensate _____ _____

polisher resin should have edequate instrumentation -

to control and monitor the cesin regeneration.

(4.7.2)

| I

10-4

__ .
_.
 . . _ _ _ _ . -_._ _ _._._ _ _ _ . . ._. . ._ _ . . _ . .
_

CHECKLIST

YES NO

DESIGN CRITERIA - POWDERED RESIN SYSTEMS

28. Condensate inlet flow distributors must be _____ _____

designed to prevent flow impingement on the

precoat; axial flowrates between the precoated
septa should be kept low by providing open channels
,
la the center and around the periphery of the vessel.
(5.1.1)

29. Septum design must prevent precoat resin leakage _____ _.,___

from the polisher during transient and normal

operation.
(5.1.2)

' 30. System piping should supply both air and water _____ _____

in the reverse direction through the filter

elements to remove the precoat.
(5.1.3)

31. Sight glasses should be installed at the lower _ _ _ , _ _____

and upper ends of the septa.

k (5.1.4)

32. The precoat mixing system should be design to _ _ _ _ . _ . _____

mix the resin with slurry, using demineralized water

or condensate as the makeup, and deliver the slurry
- to the service vessel without contamination.-
(5.2.1)

33. Precoat pump capacity must be designed to ensure _____ _____

uniform distribution of precoat on the septa and-

seal design must be suitable for pumping abrasive
.
. resin slurries.
-(5.2.2)

34. The holding pumps should be designed to provide

.
_____ _____

sufficient flow to retain the resin precoat on

the septa.
(5.2.3)

10-5

, - . . . . . . -- .
 .._ - _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ . _ _ _ _ _ . _. _ ._.

1
1
a

CHECKLIST

YES NO

35. Resin strainers should be designed to withstand _____ _____

differential pressures equal to the total system

pressure drop and such that routine maintenance
can be performed without significant out-of-service time.
(5.2.4)

36. Resin fines filters, if desired in the system ____. _____

design, should be compatible with system pressure

drop concerns.
(5.2.5)

37. The resin precoat system should be designed _____ _____

with adequate instrumentation and grab sampling

connections to properly monitor the system
performance.
(5.3.1)

OPERATING AND MANAGEMENT CONSIDERATIONS

38. Management auld clearly support operation _.___ _____

of the polisher system to achieve the water chemistry

recommendations of Reference 1.
(6.1.1)

39. Management must commit the necessary resources _____ _____

*
to provide proper training for operators and
maintenance personnel.
(6.1.2)

40. Management should ensure that resources are _____ _____

available to properly maintain condensate

polisher system
(6.1.3)

OPERATING CRITERIA - DEEP BED POLISHER SYSTEMS

41. The polisher vessel service run should be _ _ _ . _ _____

terminated when the vessel differential

pressure increases to 45 psi, or when the
ammonia or sodium starts to break through the bed.
(7.1)

10-6

- _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ . _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ . _ _ _ _ _ _ _ _ . _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __ _. _ _ _ _ __ _ _.
_-. .
-- .
. -_

CFiECKLIST

YES NO

42. Condensate Dow through all service vessels _____ _ _ _ . . . _ y

should be periodically equalized (balanced).
(7.2)

43. Hold points in the automatic regeneration _ . _ _ _ _ _____

process should be implemented to allow visual

'

inspection.
.
(7.3)

44. The exhausted mixed-bed resins should be air _____ _ _ _ . _ j

scrubbed approximately 10 minutes at an air
flow of 6.5 to 11.5 scfm/ft2 (2 - 2.5 standard
cubic meters per square meter) of vessel cross
sectional area.
(7.4)

45. The backwash and settling procedure, adjusted _____ _____

to give the maximum bed expansion allowed by ,

the cation vessel freeboard, would be performed

twice.
(7.5)

46. The anion resin transfer process should be _____ ______

conducted with safeguards to insure minirnum

amounts of cation resin is carried over.
(7.7)

47. c ering a conventional regeneration, sulfuric _____ _____

ecu concentrations of 6 to 10% by weight and

soutum hydroxide, generally " rayon quality"
or better, concentrations of 6 to 8% by weight
are recommended.
(7.7)

10-7

_._. _ _ _ _ _ _ _ _
 . . -.- - . -. -- . - . -.- - . - .-- -- - . . ..

_. CHECKLIST

YES NO
48. Regenerant parameters should meet or exceed _____ ._____

those listed in the following table:

Loading - 12lb/ft 3(200g/l)

.

Contact Time -'30 minutes minimum

Injection Time - per manufacturer's recommendation -

' Temperature - 95-120 F (35-50 C)(caustic only)

-

(7.8)

49. The regenerated resins first should be cinsed _____ _ _ . _ _ _

slowly to displace the regenerant and then -

rinsed for 10 minutes at 4 to 8 gpm/ft2 (160 to

2
320 liters /m -min).
(7.9)

50. Following the regeneration and rinse cycles, ___ _ _____

the resin should again be air scrubbed for

-10 minutes and backwashed.
- (7.10) -

51. The cation and anion resin; should be rinsed _____ _ _ _ _ .

at 4 to 8 gpm/ft2 (160 to 320 liters /m2 -min)

to a 30 uS/cm end point for the cation resin and
10 uS/cm for the anion lesin.
(7.11).

- 52. A visual inspection should be performed after _____ ____

and to insure complete resin transfer.

. (7.12). _

53. The resins should '>e mixed by draining the water _____ _____

level to the top of the resin bed and injecting

air into the bottom of the vessel at 6 to 12
2 3 2
scfm/ft of vessel area (2 to 3.5 std m /m -min)
for 5 to 10 minutes.
(7.13) -

10-8

_ _ _ _ _ _ . _
 - - _ - . _ - . . - _ - ..._- _- . .-. . -
-

CHECKLIST

YES NO

54. The final rinse of the regenerated resin should _____ _____

involve a slow fill of the mix / storage vessel

' 2
and downflow rinse at 4 to 8 gpm/ft (200 to 320
2
liters /m -min) to a conductivity end point of
-
0.3 uS/cm.
(7.14)

- 55. The regenerated resin should be transferred _____ _____

to the polisher vessel, carefully mixed, and

prepared for service.
(7.15)

OPERATING CRITERIA - POWDERED RESIN SYSTEMS

56. A polisher vessel should be removed from _____ _____

service when the pressure drop across the

precoat approaches 25 psi or when the effluent
water quality is insufficient to meet the
: chemistry recommendations of Reference 1.
(8.1)

57_ The flow rate through all filter /demineralizers _____ _____

should be periodically (and maintained) balanced.

-(8.2)

58. Backwash water flows for removal of precoat _____ _____

media should be in the 0.5 to 1.5 gpm/ft2-

9
(20 to 60 liters /m -min) range for 10 to 15
-
- minutes; air flow rates of 0.1 to 1 scfm/ft2
(30 to 300 liter /m2 -min) will be required.
, (8.3)

59. Filter element loadings should be 0.2 to 0.3 _____ _____

1

2 ;
lb dry resin per square foot (1.0 to 1.5 kg/m )
2
for startup operation and 0.15 to 0.2 lb/ft
for normal operation.
(8.4)

| j
| 10-9 |
|
!

____ _ _ -
_-_ -_ ________- - - - - _ _ - - - - - - - - - - - - - - _ - - - - - - - - - - - - - - - - - - - - - - _

ClilICKLIST

YliS NO

60. it.e resin slurry should be carefully prepared _____ _ _ _ . _

in the mixing tank. 7''

(8.5)

2 - N'
61. The precoat flow should be 1 to 1.5 gpm/ft _ ___ _____

2
(40 to 60 liters /m min) for precoating the
-

process vessel septa.

(8.6)

62. The new pre, s.at should be maintained in the _____ _____

" hold modv mr twv hours or longer.

(8.7)

63. Condenser leaks should be fixed rather than ____ _ _ _ .. _

attempting to bodyfeed resin into the filter /

dctmineralizer to acquire more ion exchange
capacity.
(8.8) ; ;
S%:

vi
i
I

- L:

L.

10-10
.

_ m,_ _ _ . _ - - - - - - - - - - . - . - - - - - . - - - ~ - - - - - - - - - - ~ ~ - - -
 - . . _ - . - . - .
- - - . . - - _--..-----

APPENDIX A (
DISCUSSION OF DICTRIllUTORS

Th uniform resin bed depth on a flat screen support with a flow distributor '
underneath giv4 the best approximation of uniform flow through tl.e resin bed.
Either laterala or nozzles are acceptable providing they are designed to give good
flow distribution.

Problems are created by the use of dished support plates, curved hub-laterals on the
'
hemispherical vessel head, or laterals or nozzles that are above the resin support
plate. A level interface is impossible with dished support plates or curved laterals 1

'
because of uneven flow stribution. Areas between and below the laterals can be
stagnant, and will not receive sufficient flow during the backwash step to separate
the resins. The anion resin remaining in the stagnant area will be converted to the
- bisulfate form by the acid regenerant, and become a source of sulfate when the
regenerated bed is put back in service.

OTIIER SUGGESTIONS

1. An indhpene nt air supply for , 9olisher and regeneration vessels, to mix-

- resins. ;

2. The cation vessel must have sufficient volume to hold one charge of mixed
'
condensato polisher resin plus head room (freeboard) to 1100% expansion of
the resin below the backwash collector.

3. . Header laterals, which have approximately 6 in. (~15 cu) long drop-legs
o designed far horizontal flow of sluice water and resin to the lower end are
recommended. The lower end of the dropleg should be located about 3 in. . - ;

(~8cm_) above the design location of the cation / anion resin interface and the
drop legs spaced at no greater than 1 ft. (~30 cm) intervals.
4

,
.

A-1

...,a.. _ _ _ _._ u. _ . _ _ __.. _._ ___._ _ _ ,_. _ .,_ _ _

 - . , s-u-, 43#Aoa 4- A A. .am a. 4 A A wma_.,a---AaM- , M 4 44 #s.M&.m 4+M dl emg 7&,= *g-hasAM_Ls 4_W4 S2a e ta.h u nd m_d._m.a47m,e 23A_M4&+J4,aa&da M_3. 4 _4M4go-m,34.,.,p,..AW pQ4p

<
1

l
1

.
.

1
i
r

k
-

|
1

I
1

<

I
i

1
i

!
e

(
l
?

!g
r

s
&

i
li
i

i-
! a

l
t

(
i;

y
-

r e-- = ----r- 6 m~-e n ,-, m.w. .e-, e,.v.~,-.. . -- ,.-r.~.-+.-m., --+-w-- w vc-v < r.:- ., . . ..e,---, - -e.e - e - r r-- %,# v- r, a . *tw .=,v.:y-.re- s -a---- w
 -

APPENDIX 11 .

ION EXCllANGE RESINS

1) Commercial kEins
Ion exchange manuf acturers recommend styrene-divinylbenzene copolymer based
resins of the strong acid and strong base type for condensate polishing applications.
lon exchange capability for strong acid cation resin is provided by the aryl sulfonate
'
functional group; the quaternary ammonium group provides such capability for
strong base anion resin. Commercial condensate polishing resin beads generally
,
range between 50 and 18 mesh (0.3 to 1.0 mm diameter) and may be either gel-type
or macroporous resins. Gel type resins have no true porosity. Macroporous resin
beads are formed from gel microspheres and have considerable porosity. Powdered
resins are gel type resins ground to less than 200 mesh (0.07 mm diameter).

Condensate polishing resins act concurrently as filters of crud (particulate corrosion

products) and as ion exchangers. This combination of properties reduces the input
of condensate system corrosion products and lanic impurities to the steam
generators.

2) Iype of Mein
Recommendation

11ead resins in deep bed condensate polishers offer the best combination of ion
exchange and filtration capabilities for PWR condensate peilishing. Gel type bead
resins are recommended for this application to take advantage of their high capacity
and regeneration efficiency. Powdered resin precoat filters can be employed where
filtration is the major goal, i.e., when high efficiency removal of loaic contaminants
is not considered necessary to protect the steam generators. A precoat of powdered
resin or a mixture of i on exchange resin and fibrous material may be used.

DIEGSsion

2.1 }'iltration
- lon exchange resins remove suspended solids by normal filtration phenomena and
by the interaction of the resin surface electrical charge with the charge of the
suspendec' solids. Cation resin exhibits better corrosion product filtering
characteristics than anion exchange resins because of their higher surface area per
unit volume and smaller bed pore size. The use of precoats with a blend of fibers i

and powdered resin will give better filtration characteristics and reduce precoat
cracking problems. Piccoats of pure powdered resin normally are used when
suspended solid concentrations are low and more ion exchange capability is desired.

Ib1

_ _ _ _ _ _ _ _ _ _ _ _ - _ _ _ _ _ _ _ _ - _ _
 _ _ - . _ . _ _ _ _ _ . _ .,.

PWR polisher corrosion product performance has been investigated and the results ,
'

summarized as follows (1):

1) Feedwater iron transport to the steam generators can be reduced by 30 to 50%

by full flow condensate treatment. Similarly, average copper and nickel
inpu s can be reduced by 75 to 90% and 20 to 50%, respectively.

2)' Deep bed polishers have removal efficiencies of 60 to 85% for iron,75 to 93% .

for copper, and 70 to 90% for nickel.

3) Powdered resin polishers have removal efficiencies of 87 to 99% for iron,81 .

, to 87% for copper, and 40 to 55% for nickel. .

4) Powdered resin polishers were more efficient than deep beds for removal of
filterable species, which constituted the major fraction of the condensate
corrosion product transport.

5)= Transport during transients is better controlled by powdered resin polishers

than deep bed systems.

Ehher deep bed or powdered resin polishers are effective in reducing steam
generator corrosion product input and, by reducing the quantity of sludge in steam
generators, will help control steam generator corrosion.

The resul's indicate powdered resin is more effective than deep beds for iron
removal. However, incomplete removal of corrosion products from deep beds
during the regeneration process contributes to the wide variation in observed iron >

removal efficiency (60 to 85%). Vigorous scrubbing, and extension of the backwash
until all the loosened corrosion products on resins and can be used instead of air
. scrubbing. Improved cation resin cleanliness also will be achieved with the use of
hydrochloric acid instead of sulfuric acid regenerant.

There was little difference observed in copper removal by deep beds and powdered
resins, and the deep beds were more effect!ve for nickel. Minimizing steam
generator copper input is of particular importance. Copper ion is a very powerful
oxidant in high temperature water and is reduced to metallic copper in the steam
generator where it deposits as such atop magnetite (2). There,it promotes and *

enhances the fast linear growth of nonprotective magnetite from the mild steel
substrate, which is the type of carbon steel corrosion in the tube-to-tube support
L plate crevice that causes tube denting Q)(4),
1

U2

..
_p.v- c.7.y..,_..-,, - - _ - . - , , , . , . . . . , . _ . _ m , , ,, . . , _ . _ , , , , . . , _ , ,..,mm..mm,m.,,,,,, ._ m. . , ~ .m, ,w. .w-.
 ._._ _ _ ._- _ . . _. _____.__ ..__ _._.__._ . __._

L2 lon Exchange _}<inetics

The higher surface-to-weight ratio and lower mean distance of the exchange sites
from the surface of powdered ion exchange resins suggests these resins should
demonstrate improved kinetics when compared to the larger bead resins. The effect
of particle size on kinetics is demonstrated in Figure B 1. For a constant super.'icial
flow, a bead resin bed depth of approximately 100 times that for powdered resin is i

*
required for the same resin utilization (i.e., powdered resin utilization is equivalent
to that for bead resin at 2/100 the bed residence time). The improved ion exchange
kinetics allows similar impurity removal efficiencies with 0.2 to 0.4 in. (0.5 to 1.0 cm)
,
thick powdered resin precoats and 1.5 to 3 ft. (0.5 to 1.0 m) bead resin bed depth. i

Kinetic properties of the same type of ion exchange resin can differ between
manufacturers and batches of an individual resin (6,Z). In addition, kinetic
performance of bead resins can deteriorate with extcnded usage because of
contaminant accumulation. Anlon resins are susceptible to fouling by organic
matter and iron, and loss of salt splitting capacity. These effects reduce the rate of
ion exchange and increase anionic slip through the bed at fixed flowrate. At the
2
current condensate polisher design flowrate of 50 gpm/ft2 (2040 liters /m -min),
anion resins are operating near the limit of their kinetic ability Q. Therefore, it is
important that the best available materialis used, and the anion resin is tested
regularly for performance. If organic fouling appears to be a problem,it is better to
delay buildup of foulants by regular treatment with brine solutions or some other
cleaning agent than to allow continued buildup (H). The accumulation of organic or
iron foulants on the anion resin bead also increases bead density, making the resin
more difficult to separate from the cation resin, and increases post regeneration
rinse times.

The copper, iron and nickel oxides, and silica removed from the condensate can
sometimes accumuiate on the cation resin. This surface fouling degrades cation
resin kinetics and filt tring efficiency. Vigorous scrubbing and backwashing during
each regeneration w'il minimize corrosion product fouling. Treating the resin with
dilute hydrochloric acia is often effective for removing corrosion products (_8). De-
crosslinking of the cation rosin as it is oxidized in continued service can be a source
,
of anion organic foulant. It is important to test both cation and anion resins in
,
order to identify possible problems and advisabihty of resin replacement.

There is some evidence that resin bead spacing and charge effects in a mixed bed
degrade resin kinetics, suggesting that placing of cation and anion resin in separate
beds would give improved performance (9). This also would simplify the-
regeneration process. However, pickup of sodium by the anion resin during
regeneration will lead to sodium leakage from the anion bed (10).

B-3

,-w,-m- -r w v v -. -, ., = ,e + - ~ - - e- , .-....,,4----.m,------ -4,..~. - e-r %--,-, , v.-u,m-,- . . - .,---ee . - ee-

_ - .- __ .____..__-.__.m . _ - - _ _ _ _ - . _ . . _ . _ _ . _ _ _ . _ _ _ _ - - . . _ _ _ - -
-

i
f
,

100 i i , , , , , ,

. ,

90 -

Ikd Depth *

4 ft (1.2 m)
e 80 - _

$
471

E 70 -
N Precoat rhickness _

j N 0.6 in (1.5 cm)

2 ft (0.6 m)
_

1
1 50 -
._
:p

i .25 in (0.64 cm)

t 40 - _

8
e
h 30 -

20 - # PP* I# _

Dead Resin Powdered Resin

(20 25 mesh) (325 mesh)
10 -

0 t , i , , , , ,

10 20 30 40 50 60 70 80 90 100
Flow Rate, spm/ft'
;

Figure B 1. Variation of Resin Utilization with Flowrate

'

B-4

_ . _ . _ ,. . .. _ - . .. .- . -- .- .- - - -
 --_- - _ . -

Thus, unless a prolonged anion rinse of several days is provided a third bed
containing cation resin follmving the anion bed would be required to obtain
: acceptable water quality (11)

2.3 Capacity ,

The excellent kinetics of powdered resins allows operation with 0.25 to 0.5 in thick
2
. precoats at superficial flows of approximately 4.0 gpm/ft2 (160 liters /m -min). !
When operating with ammonia to control pH between ammonium form is in the
range of 2 to 20 hours. There is little advantage to operating with hydrogen form
, cation resin because most impurities removed during hydrogen cycle operation are '

cluted when the cation resin converts to the ammonium form. Consequently,
powdered resin polishers are operated with ammonium form cation resin unless a
small amount of hydrogen form is needed to control pH.

Both gel-type and macroporous resins are used for deep bed condensate polishing.
There are different types of macroporous resin available. The so called "first
generation" or "macroreticular" resins were bundles of small, highly crosslinked
microspheres stuck together to form a bead (12,la). "Second generation"
macroporous resins have lower porosity and a greater amount of gel phase matter
in each bead. The crosslink levels also were reduced in the second generation
macroporous resins, and their properties are intermediate between those of the gel- 1
type and. first generation macroporous resins.

Capacities of standard' gel type resins generally are higher than those of
macroporous resins. Both the total and operating capacities of gel type cation and
_

anion resins are higher, primarily because of the lower crosslinking. 'Ihe differences
in operating capacity among various mixed beds can be as much as 50%.
Furthermore, gel type resins have more favorable regeneration efficiency than
macroporous resins. This better efficiency can be particularly important after a
condenser leak. The attrition of macroporous resins appears to result in more small
colloidal particles (that can be carried out of the polisher vessels _with the
condensate) than come from the gel-type resins (11).
.

Type-1 strongly basic anion resins and strongly acidic cation resins tend to break r

down with continued use. Cation resins decrosslink from oxidation resulting in
* ' increased water retention and a decrease in density. However, since condensate
- oxygen levels are low, oxidation of condensate polisher cation resin is not a serious
: problem. To obtain good separation between anion and cation, the more dense 10%
crosslinked gel type cation resin should oe used in preference to 8% crosslinked. -
Anlon resins are less stable than cation resins. Over a period of several years, the-
anfon resin loses some of its total capacity and some of its strong base capacity.-
_

L Strongly basic groups break down to weak base groups, and the latter can increase to
20 to 30% of the total capacity over the life of what was originally a strongly basic
,

L B.5

v . e-'-s -e e ,va,wm,-, ne,,mv,-~ e-.-n.mn -. .e y sw.mv.,n.,,,,,,,,. s e - w r. , m,--,Am..,ve,-n,--n-n-,--+-e---n,ewww a , ~ ---e v- e

 _ . _ _ _ _ . _ _ _ _ . _

'I

anion resin. The weak base groups adversely affect the anion resin kinetic
performance and salt splitting capacity.

2.4 Q11cmilon With Ammonium Form Cation Resin

The degree of regeneration of cation and anion resins required to maintain bed
effluent sodium and chloride equilibrium leakages of 0.3 ppb were calculated using
the methods of References 14,15, and 16. Results are given in Table 111.
*
TABLE 31 !

DEGREE OF REGENERATION TO ACIIIEVE '

SODIUM AND ClILORIDE LEAKAGE OF 0.3 ppb

Ilydroxide Cation Resin

pil Form Anton Resina 7sjkgeneration E0nn
7.0 39 84 1I

8.8 97.5 99.8 NI1 4

- 4.0 98.5 99.9 NII 4

9.2 99.0 99.94 NJ1

4

9.4 99.3 99.96 N11

4

- Obtaining these levels of regeneration would require unrealistically high quantitles

of regenerant chemicals. As such, ammonium form operation with deep bed
. polishers should not be attempted. In addition, new powdered resins can throw
impurities when operated at high pII unless high purity resins are used. Figure 112
shows that insertion of three freshly precoated :ondensate polishers increased steam
generator blowdown chloride levels from 10 to 30 ppb 02). These blowdown *

chloride concentrations are above the 20 ppb normal operation guideline Q3).
Reduced chloride throw could be achieved with the use of commercially available *
law chloride (<0.5%) mion resin. Steam generator blowdown sodium levels were
- in the 19 to 15 ppb range before insertion of the polishers and did not change
_

significantly after the polishers were put in service. It should be noted, however,
, that the actual steam generator blowdown rate could rN be guaranteed because of
i
difficulties encountered during the startup of the new m generator blowdown
!
recovery sy: tem,

,
,

Il-6

I
- . - .. - - .. - . . . - - - - - . - _ - . _ _ _ - _ _ . _ - - . _ .
 _ _ ..- __ ..__ . . . _ . _ . _ _ _ - _ . . _

I I I i i
|
.

'
.o e
& 40 J -

i "! -

8 h
d S/G A
-
T 30 -

a
$
b'e
E 20 -
-

'h
p u ,

.,

i
.$
J 10 -

0 ] | | | |

0 10 20 30 40 50
*

Operating Time, h

'

| Figure B-2. Chloride Breakthrough from Powdered Resin

| Polishers Operated at pH of Approximately 9.0
|

1.

I
|

'

B-7

. . - _ . - . . _ _ _ ._ __ _ . _ _ . _ ,
 ~ - - . - - - __ - .- -----

Since conversion of powdered resins to ammoniuni cycle operation is relatively

rapid, efficiency of such systems for removal of low concentrations of ionic |
impurities from condensate generally will be insufficient to meet the PWR Steam |

Generator Owners Group Water Chemistry Guidelines during condenser leakage )

events. !
|
'
2.5 Resin Regeneration |
!
Elution of sodium from cation exchange with sulfuric acid is shown in Figure B 3. |
Sodium removal becomes more difficult with Figure B-2 chloride brec.kthrough '

|
from powdered resin polishers operated at pH of approximately 9.0 increasing
divinylbenzene crosslinking G2). The normal 8 to 10% crosslinked gel-type resins *
are regenerated considerably easier than the macroporous resins which may have
up to 20% crosslinkmg. The relative selectivity of sodium and ammonium ions as a <

function of crosslinking is shown in Figure B-4. The selectivity for ammonium ion
relative to sodium increases with crosslinking. Thus, as crosslinking increases, the ;
difficulty of regenerating ammonium form cation to hydrogen form increases faster t

-than for sodium. The combination of the higher ultimate capacity and regeneration
efficiency for gel-type cation resin results in considerable higher operating capacity j
than can be achieved with macroporous resin. The higher operating capacity
translates into longer hydrogen cycle run lengths.

A comparison of chloride clutfor. curves for various new, type-1 strong base anion
_

resins is shown in Figure B-5. Again the gel-type resin exhibits the highest capacity
for a given level of sodium hydroxide regenerant. Thus, the comments regarding
operating capacity for cation resins apply to the gel-type anion resins.

2.6 Post Receneration Rinses -

As condensate polisher efflu2nt requirements become more stringent, additional

focus has been placed on sulfate throw from a freshly regenerated bed. New type-1
strongly basic anion resin normally contains less than 1% weakly basic groups.
Under use conditions, strong base groups gradually degrade to weak base groups.
Anion left in the catior vessel during regeneration is converted to the bisulfate
form lipon rinsing, the bisu! fate is converted to sulfate and an equivalent of acid is .

released.. This icaction is fairly rapid and the bisulfate is converted to sulfate in a
fairly short rinse 09). Strongly basic groups will retain the sulfate in preference to
most other anions. However, the salt form of the weakly basic group is stable only .

-in acidic solutions. Therefore, as the pH increases with continued rinsing, the
weakly basic salt groups are hydrolyzed and release additional acid. The hydrolysis
reaction is relatively slaw, and a prolonged acidic bleed from weak base sites occurs
with continued rinsing.

B-8

- _,_ _ , . , . _ . _ _ _ _ _ _ _ _ _ . - - _ - _ _ _ _ _ _ _ _ _ . . . _
 __ __ _ _ _ _ _ _ _ . __

100 , , , ,

\
\
10 20% DVB
-
\ _

e \
\ 12% DVD
.d
y 1.0 -
\ _

s \ .
10% DVB Cel(Winh)
.h
8% DVD
~ _

0.1

0.01 I \ l I l

0 25 50 75 100 125 150

ReBenerant level,Ib 9F% ISSCA/ft'

,

Figure B-3. Elution of Suuium ham Cation Resin

.

|
|
|

B-9
|
|

- --
 . _ - - _ _ _ _ _ _ . - _ _ _ _ _ _ _ _ - - _ - _ _ - _ _ _ _ _ _ _ _ _ - _ _ _ _ _ _ _ _ - _ _ _ _ _ _ _ _ - - _ _ _ - _ _ _ _ - _ _ _ - - __ _ _ _ - _ _ - _ ___ _

i i I I "I
4.0 - -

Nil! -

3.0 -. -

Na
..,
M
b
2.0 - -

Sekoivity of resins for ammonium ion

increases relative to sodium ion as the
1.0 - resin crosslinkage increases.

i'
1

0
(
'
i i i i i

0 4 8 12 16 20
Crosslinkage, % DVB

: Figure B-4. Dowex Resin Selectivity vs. Crosslinkage

|

U-10

. _ . . . . . . - . , . - .
. ..

I I I I
'
1,0 -
-

0.8 -
-- -

30.5 -
n
-

li
A
X
-

0 -
.g 0.4 -
-

5
4
3
d A - SnR-P, Porous Cel
U SDR,GelType
-

0.2 _.
._

C . MS A 1, Macroprous

.
O l I I l
0 2 4 6 8 10

Regeneram ; vel,Ib Naoll/ff

. o

1:igure 11-5 Typical Chloride Elution Capacity

of Type 1 Anton Resins

11- 1 1

.
- _ _ _ _ _ _ _ _ _ - _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _
 _ _ _ _ _ . _ -
__ _ _ _ _ . . _ _

When the resins are mixed, some a.,ian beads containing sulfate end up on the
bottom of the bed. During the rinse, acid released from the bottom layers of the bed
is not completely exchanged by a regenerated hydroxide form anion resin head. i

Wi;h new anion resins, the effect is not large because of the low content of weakly
basic groups cnd good kinetics. As the anion resin ages, additional weakly basic
groups form and organic fouling may
occur. The weak base groups and fouling impairs anion exchange kinetics. This
results in a higher level of sulfate which must be rinsed out of the bed (1519).
Either rinse time must be increased or additional sulfate is released to the polished :
'

condensate. The recirculation rinse scheme provides an extended high flow rinse ;
method without the necessity to disca d rinse water. However, fouled anion resin i

eventually will need replacement because the slip of all anions increases with
kinetic fouling.
,

|
The combination of good separation, sufficient rinsing, and anion resin replacement
will minimize sulfate breakthrough.

The rate of anion fouling will vary from plant to plant. Anion resin replacement
should be based on resin analyses and sulfate rinse characteristics.

3. Resin Purchase Specifications

- A resin specification should accompany the purchase of any ion exchange resin,if ;
--optimum performance of a condenst.te polisher is desired. The buyer should make !
certain the specifications are met and reject material that is out of specification.
3.1 Powdered Resins
'

Recommendation
,

Powdered resin specifications like those shown in Table B-2 are recommended. :

D.iscussion

The specifications in Table B-2 generally should be applicable. Variations in ,

equipment or operating conditions may impose different property requirements in

some cases. For example,in the case of precoat cracking problems or heavy crud
'
loadings, one of the commercially available blends of fiber and resins may bc .

desirable. However, high regeneration levels, and low resin chloride and sodium
concentrations are required to minimize impurity throw from the resins, because
the polishers normally operate with ammonium form cation resins.

B-12 <

.. . - _ _ . . - . = - . = .- -__..- -. -- . - - - - . . . . _ - _ - - - . . . - . - - a -- _-
, _ _ _ . _ . . . . .

_ . . . _

Table B-2

POWDFRED RESIN SPECIFICATIONS

Anion Cation Lation Procedure

Resin Type Strong Base 5trong Acid Strong Acid -----

.

Total Capacity, meq/ dry 9 >4,0 >4.5 >4.8 ASTM 0-218?(2_4,)

, lonic Font Hydro side lemonium Hydrogen -----

Moisture (Average), % 55-62 51-57 55-62 ASTM 0-2187

Site Compoe.ition,% >95 OH~ >95 NH'4 ,,99

> H* ASTM D-2187
'

<0.5 Cl- <0.1 Na* (0.1 Na* -----

Whole Beads, % <5 (5 <5 ASTM 0-2187

>

G
4

4 .

13 - 1 3

.. - _ _ _ _ _ - _ _ _ _ _ _ _ _ - _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _
 _

52. Lt:'d ite<. ins

_

Jtecolumendation

Specifications similar to those in Table B-3 are recommended for purchase of new
resius.

Discussion

Wet volume capacity, regeneraied fraction, moisture content, and screen analysis
are tests normally performed by the resin ,

manufacturer, in addition, a crush strength test ensures adequate resistance to

physical attrition. Assurance of good kinetic performance of the resins is provided (,.
by the dynamic capacity test. Variations in equipment and operating conditions may [
necessitate changing property requirements in Table B-3. ~

4. Periodic Testa Of _Used Itesins

Recornmc0_dMLo_n

Tests listed in Table U-4 are recommended for representative samples of separated
cation and anion resins after they have been regenerated and rinsed.

Discursion

The caustic float tests serve as an evaluation of separation efficiency. The salt
splitting c..pacity gives information on degree of regeneration and available
operating capacity. These tests provide data on resin cross contamination and
regeneration allowing early identification of potential problems.

Semiannual test data on resins that are in use allows comparison to the new resin,
and provides a basis for deciding when operating modifications are required at
resins should be replaced.

5. Resin Sampling

Recommendation .

The regenerated, rinsed resin in the cation and anion vessel should be air mixed.
Sampling of the resin during transfer to the storage vessel is recommended. Six or
more samples of the resin slurry should be taken from the resin transfer line at
approximately equai intervals during the transfer.

Equal volumes of the individual samples should be b! ended to obtain a

representative sample for analysis.

B-14

- _ _ _ _ _ _ - _ _ _ _ - _ _ _ _ _ _ _ _ _ _ _ _ - _ _. _ __ . _ - -
 -

Table B-3

BEAD RESIN SPEClflCATIONS

(Test', performed on resins in hydrogen and hydroxide form unless otherwise

indicated.)

Cation Resin Anion Resin Procedure

Polystyrete Polystyrene
'

Resin Type ----

4 5trong Acid or Base Capacity, >1.9 >1.0 ASTM 0-2187(24)

-
r, :q/mi

!?lt Splitting Capacity, meq/ml 1.9 >0.98 ASTM D-2187

Fraction H or OH Form, % )95

,
>85*
,
ASTM D-2137

fraction ^,i- Form, % <5 Appendix 0 ,

Moisture Retention Capacity, ~<55 <60 ASTM 0-2187

wt. % (Cl ~f orm)
Particle Size (Wet), volume % AST'. D-2187
- Retained on 16-mesh <2 <1
Through 40-mesh T2 T5
Through 50-mesh 70.5 70.5
Crush Strength (20-30 mesh), g/ bead Appeniix B
Average of >60 beaos
-
>350 >350
Minimum for 95% of beads >200 >200

Dynamic Capacity (3 ft mixed-bed with cation-to-anion equivalent Appendix C

ratio = l i influent 10 ppm Nacl in pH 9.0 NH 4 0H operated at
50 gpm/f t'l^
Sodium Leakage at 40% of Cation 0.1 ---

Capacity Exhausted to Sodium, %

Chloride Leakage at 60% of Anion --- 0.1
-
Capacity Exhausted to Chloride, %
* Chloride form anion resin shoul ' be avoided whenever possible, if chloride form
- is purchased, a two-step regeneration should be used (i.e., conversion to 504 or
C03 form then regeneration with NaOH)

Dk15

|
- -- _ _ - - _ _ - _ _ _ _ _ _ - - _ _ -
 .
.

1.

Table B-4

CONDENSATE POLISHER USED RESIN TEST .

Sample Test Descripticn Frequency procedure

Cation and Caustic float a portion of Every 4th re- ASTM D-2187
-Anton each sample to determine generation of
^

resin cross-contamination. each-batch

Measure operating capacity
of each resin with salt-
- - -

-splitting capacity-test.
_

Cation and a) Tests in Table B-3 Semiannual -~---

_ Anion b) Total capacity ASTM D-2187

c) Iron contamination |8's
d) Sodium, magnesium, and Appendix D
calcium on cation resin
e) Chloride and sulf ate in Appendix 0
anion resin

#
r

('

B-16

- ___ _ _ _ _ _ _ _ _ ___--____-________---____- _ _ _ _ _ _
 ,

12iEG1Ehm

Procedures for obtaining representative resin samples are given in ASTM D-2687
(2@, llowever, the procedures require opening of the vessel to take a core sample.
An operating power station cannot continuously open the regeneration vessels to
obtain core mmples. The suggested method it, an on-line sampling procedure that
will give a reasonably representative sample. An exact sample is not required to
follow the general operation of the polisher system and identify potential problems.

B-17

__
 - -____

|
|

REFERENCES

1. Sawochka, S. G., et al., " Corrosion Product Transport in PWR Secondary

Systems," Electric Pow r Research Institute, December 1981 (NP-2149).

2. Passell, T. O., " Copper Attacks Gold in liigh-Temperature Water," EPRI

Journal,2, p. 42, October 1977.

3. Potter, E. C., and Mann, G hi. W., "The Past Linear Growth of hiagnetite on
hiild Steel in High Temperature Aqueous Conditions," Beit. Corr. J.,1, pp. 26-
35,1965.

4. Economy, G., et al., "PWR Steam Side Chemistry Program," Electric Power
Research Institute, August 1982 (NP 2541).

5. Strauss, S. D. et al., "lon Exchange," Power,124, pp. S.1 S.16, September 1980

6. Siegwarth, D. P., et al., " Performance of Condensate Deraineralizer Dead

Resins," Electric Power Research Institute, (NP-3036) to be published.

7. Ray, N. J., et al., " Kinetic Performance of Anion Exchange Resins," Proc.
International Water Conf.,42, pp. 307-313,1981.

8. Ball, hi. and Ray, N. J., "An ion Exchange Resin Testing Service--hiethods and
Firdings," Effluent and Water Treatment Journal,16, pp. 73-81,1976.

9. Smith, J. II., "Mixe-1 V Shigle Bed lon Kinetics," Proc. International Water
Conf., 43,1982.

10. Siegwarth, D. P., et al., "A Review of Condensate Demineralizer Regeneration

Procedures," Electric Power Research Institute, April 1983 (NP-2975).

11. Mickel, R. E., et al., "A Different Approach to Condensate Polishing," Proc.
International Water Conf.,42, pp. 209-215,1981.

12, McGarvey, F. X., and Gottlieb, ,M. C., " Fundamental and Basic Theories
Regardmg the Proper Use of Modern Day lon Exchange Resins," Proc.
International Water Conf.,40, pp.175-182,1979.

13. Kunin, R., " Twenty Years of Macroreticular Ion Exchange Resins," Proc
International Water Conf.,40, pp.183-187,1979.

14. Abrams,1. M., "New Requirements for Ion Exchange in Condensate Polishing,"
Proc. International Water Conf.,37, pp.165-174,1976.

B-18

_ - - _ _ - _ _ _ _ _ - _ _ _ - _ - _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ - _ _ _ _ _ _ _ _ _ _ ___ _ _ _ _ _ _ _ _ _ _
 ___ _

|
|

15. Emrnett, J. R., and Grainger, P hl., "lon Exchange hiechanism in Condensate
Polishing," Proc. International Water Conf.,40, pp. 81-88,1979.

16. Salem, E., "A Study of the Chemical and Physical Characteristics of lon
Exchange hiedia Used in Trace Containment Removal, " Proc. American
Power Conf., 31, pp. 669-684,1969.

17. Gould, A., Florida Power and Light, Personal Communication, September 1982.

18. "PWR Secondary Water Chemi: Guidelines," Rev.1, prepared by the Steam
Generator Owners Group Water Chemistry Guidelines Committee, hiay 1984.

19. liarries, R. R., and Ray, N. J., " Acid Leakage from hilxed lleds," Effluent and
Water Treatment Journal,18, pp. 487-995,1978.

20. 1902 Annual Dook of ASThi Standards, Part 31, Water, American Society for
Testing and Materials,1982. ,

B-29

l
'

_. . __ __ . - _ _ _ _
 . .
.
,

Al'I'liNI)lX C

Rl!Gl!Niil<ATION l'ROCl!SS I)l!SCl(IPTIONS

The exhausted ion exchange resin is transferred in a water slurry f rom the deep bed
polisher vessel to the cation vessel for regeneration. If a spare charge of ion
exchange resin is available in the mix / hold vessel, it is transferred to the polisher
vessel and the vessel is held in standby. Tht major steps in regeneration of the
exhausted resin are as fobows:

, 1) Air scrub and backwash the resin to remove particulate corrosion products
from resin surface.

2) llydraulically separate anion from cation resin with upflow of water. The
anion resin, being less dense than the cation resin, migrates to the top of the
bed.

3) Transfer anion resin from the cation vessel to the anion vessel.

4) Add acid to the cation vessel to regenerate the cation resin, and caustic to the
anion vessel to regenerate the anion resin.

5) Rinse the cation and anion resins to remove residual acid and caustic
regenerants. ,

6) Normally, air scrub and backwash the separated resin for corrosion produrt
removal,
,

'

7) Transfer cation and anion resins to mix / hold vessel.

8) Air mix cation and anion resins.

9) Rinse mixed resins and hold until needed to recharge a polisher vessel.

Variations in commercially available regeneration processes are summarind as

follows:
.

CONVENTIONAL REGENERATION

Sodium leakage results from contact of cation resin with sodium hydroxide in the
anion resin vessel. Methods have been developed to minimize this leakage, which
is caused by resin crosscontamination. Generally. when the conventional
regeneration procedure (Figure C-1) is used, sulfate contamination of the anion
resin is accepted to minimize sodium leakage. Because of their relative selectivities

C-1

- - _ _ - - _ _ - - _ - _ _ _ _ _ _ - _ _
 - - . _ . . - . - - . - _ _ - - - . - - - . - . - - - _ _ . . - . . _ . . . -.

CR AR RS
5-10% 14%
CR AR RS
|go, o
NaOl {
_ , y

axx xx ->

h. k hk k
- v
1) hhausted resin transferred int
CR vessel for regeneration.
4) Realn regeneration and
rinso

Ik

+
, M
-

/sb
n.
"" ~

112 0 *

2) Resins cleaned, backwashed and 5) Cation and anion resins

hydraulically separated. Anton transferred to RS vessel,
. resin moves to top with cation mixed and rinsed. Resin
resin on bottom. batch ready for use.

.
+

"
<u ts er

3) Anion resin transferral to AR

,
vessel! casing thin layer of
( anion resin in CR vessel to .

minimize eation resin transfer

to AR vessel.

I-

CR = Cation resin regeneration vessel -

| AR = Anton resin regeneration vess.el
| RS = Resin storage vessel
i

| Figure C-1. Conventional Regeneration Procedure

C-2

. _ . _ . . _ .. _ . _ _ _ _ - _ _ . . _ _ . _ _ - _ _ _ . . _ _ _
 - --- ____

during operation, sulfate is retained on the resin better than sodium. Ilowever,
sulfate leakage, particularly after a regenerated bed is put in service does occur
because of the sulfate contamination anion resin andsulfate retention by the cation
resin. The probability of sulfate leakage increases with anion resin age (1,2).

AMMONEX PROCESS

This regeneration process was developed and patented by the Cochrane Division of
Crane Company. In the Ammonex process (Figure C-2), the anion resin iransfer is
'
stopped as near the cation-anion resin interface as possible. Since it is exceedingly
difhcult to prevent some intermixing of cation and alon resin at the interface, some
cation resin is transferred to the anion regeneration vessel and some anion resin
remains with the cation resin. To minimize sodium contamination from cation
*

entrained in the anion, an approximately 0.5% ammonia solution is circulated

through the regenerated anion resin for 3 to 10 hours to convert sodium form
cation resin in the anion regeneration vessel to the ammonium form. The
ammonium solution is recycled through the cation resin to reduce sodium levels
during the ammonia treatment step. The cation resin is regerierated after
completing the amuonia recycle step.

SEPREX PROCESS

In the Seprex process, developed by Graver Water Division of Ecodyne Cc.rporation

(Figure C-3), a portion of the mixed resins at the interface is transferred with the
anion resin to the anion regeneration vessel. The cation resin is regenerated in the
conventional manner with downflow of sulfuric acid. The anion resin is
regenerated with sodium hydroxide sufficiently dense (16 to 20% by weight) to float
the anion resin, The entrained cation resin in the sodium form sinks to the bottom
of the anion vessel. The floated, regenerated anion resin is transferred to the resin
storage vessel with the caustic solution then rinsed before combining it with the
regenerated cation resin. The sodium form cation resin in the anion regeneration
vessel is transferred back to the cation regeneration vessel where it is regenerated
with the next batch of resin.

,
INERT RESIN PROCESSES

The use of inert resin was originated by Dia Prosium in France (now Duolite
.
International SA) to minimize cross-contamination of resin in the regeneration of
mixed beds. As shown in Figure C-4, the resin mixture consists of three
components: cation, anion and inert resin. The specific gravity and particle size of
the three components are designed to hydraulically separate into three layers. The 6
to 12 inch deep inert resin layer serves to reduce resin cross-contamination.
However, Sadler, et al, have shown that in pract!ce some cross-mixing of the cation
and anion resin occurs at the interface between the ion exchange and inert resins
(11).

C-3

-- _ - _ _ - _ - _ _ - _ _ _ _ . _ _ _ _ _ _ _ _
 Nil 3 CR AR RS

CR AR RS
O ,
- . -

E e a l I
1) Exhausted resin transferred into
CR vessel for rege .cration. 4) Amrnonia recycle to remove
u>dium from ration contamination
in the AR.

5-10% 112 50,

n

l'

W/ff
"
h\b o
& W
if

2) Resins cleaned, backwashed and 5) Regeneration and rinse

hydraulically separated. Anion of ration resin.
resin moves to top with cation
resin on bottom.

4-6% NaOil

v
4
- -+

-
1

| 1 .

3) Anion resin transferred to AR 6) Cation and anion resins transferred .

vessel, and then anion regenerated to RS vessel, miud and rinsed.

and rinsed. Resin batch ready for use.
-

CR = Cation resin regeneration vessel

AR = Anion resin regeneration vessel
RS = Resin storage vessel

'

Figure C-2. Ammonex Regenera ion Procedure

C4
 ._

CR AR RS

CR AR RS II$0 4
16-207, Naoli
5 10 % o u

~ +

ff ' "

s<f> ,
T4 --

v n

1) Exhaust resin bid and Na form

resin from AR vessel transferrtd 4) Cation resin regenerated and
rinsed. Anton resin floated
to CR venel for regeneration.
- and regeneraad.

-+

b
/ d :enm

112 0 5) noating anion resin transferred

to RS vesselleaving Na form
"" " "
2) Resins cleaned, backwashed and in ri d in e'1
hydraulically separated. Anton
'esin moves to top ,,.d. sation
resin on bottom,

%
__

-+ #

*
1

- 1

3) Anton resirt including iniwd (,) Cation and anion resins transferred
. resin at interface, transferred to RS vessel, miwd and rinsed,
into AR vessel. Resir batch ready for use. ,

CR = Cation resin regeneration vessel

AR = Anton resin regeneratic n vessel
RS = Resin storage vessel

,
Figure C-3. Seprex Regeneration Process

C-5

,
_ _ - _ - _ _ _ - _ _ _
 CR AR RS

CR AR Rs 5 10 % 4-6% Naoll
11 S 0 " "
,
2 4
+

"
1) Enhausted resin transferred into ,

CR vessel for regeneration. 4) Resins regenerated and

rinsed
.

b|

--

hf
VA "
- -
% kin
112 0 ;-

2) Resins cleaned, backwashed and 5) Catton and anion resins

hydraulically separated Anion transferred to RS vessel,
resin moves to top with cation miwd and rinsed. Resin
sesin on bottom. batch ready for use.

- -.-

d
.

3) Anion resin transferred to AR

vessel. Cross contamination of
resins minimized by taking part of .

inert with anion res!n and

leaving the rest with cation resin,

CR = Cation resin regeneration vesse!

AR = Anion resin regeneration vessel
RS . Resin storage vessel

Figure C-4. Regeneration with Inert Resin

C-6

l
_ _ _ _ _ _ _ _ _ _ _ _ _ _ - - _ _ _ _ _ _ _ _ _ . _ . _ - - _ - - _
|
 --___ ____

..
C/ ~ ' :F"

*
e ~~
,

e, denloped and patented by The Permutit Company, a Subsidiary

;*7+ ' . .up . '.aveloped to minimize sodium contamination of the resin.
t iJ 'v t
parated and regenernted similar to the conventional procedure in
g ,,
.siter regen:11 tion, the anion resin, containing a small percentage of
'

_
.m the sciiu n form,is rinsed with a dilute solution of calcium
, ?
-'
e ochv son displaces the sodiuta and converts the cation resin to the
..
. 'g
ig;;., .,
jj, , selectiv'tv for calcium is greater tt an most normal cations in the >

bsa , .
" . not lil ' : displaced during the resin service cycle.
ia
. Nb .E -

m . .JCESP .5
*;q ,"
,

".
. a
'
'l Ate regeneration proce6 res are available, bus .iot widely used.
.

a eratt of reparated cation and anion resins in a single vessel with upflow of
acio and down flow of caustic has been used Q). The Conesep System v as >

M. h :!oped by Kennicott Water Treatment to improve resin separations (O. To

:aninate problems with resin separation, the Yripol process was developed and
?ented by Permutit-Iloby, Ltd. (5).
,+

* 9

:' e.

^! C-7

- , - = = - - - - - - - - - _ . . . _ _ , , _ . _ _ . , . . . , . . .
.

,.

.s +._ . .
 , ._ .. . _ . . _ _. . _ . _ . .__ _ _ . _ . _ _ _ . . .. ._. __

REFERENCES 1

1. Wolf, J. J., and Abrams, I. M., " Operating Experience with Triobed in the
Production of Ultra High Purity Water," Proc. International W&r Conf.,40,
pp. 263-267,19N.

: 2. Emmet.t, J. R., and Grainger, P. M., "lon Exchange Meclunism in Condensate

Polishing," Combustion, p.12, August 1980.

3. Sadler, M. A., et al., "A Study of the Performance of the Triobed Condensate
'
Polishing Plant Systam at Doel Pcwer Station," Nuclear Energy,18, pp. 389-399,
December 1979.

4. Emmett, J. R., and Grainger, P. M., "A Practical Solution to Problems Occurring
in the Production of L - Pure Water," BNES, Bournemouth, England,
October 14-17,1980.

,
5. Smith, J. H., anc~ /cploe, T. A., "The Tripol Process - A New Approach to
Ammonia Cvele Coridensate Polishing," BNES, Bournemouth, England,
October 14-17,1980.

L
i .

j;
s

;.
|; .1

C-8
o

_ _ _ _ _ _ . . _ _ _ - _ __.
 _ . _ _ _

:, . .; ..

: Table E-1 i
,

CONDENSATE P01.15HER. SYSTEM INSTRUMENT MAthTENANCE'

,

' Calibration -
Maintenance
'

instrument' Method Schedule- lien Schedule

' Pressure and differential Comparison to standard gauge ' Biannually Clean or replace As required
pressure gauges.. or manometer

Teraperature -

Sensing element Inspect and replace As required

Indicator / controller Compa.-ison to ' temperature Bimonthly Adjust, lubricate, etc. Per manufacturers
' standard' -instructions-
Flow
i
q Sensing element inspect, clean and replace As required
6 Zero and span adjust Bimonthly Adjust, lubricate,etc. Per enanufacturers
Indicator / controller
instructions
Totalizer Zero and span adjust Monthly Inspect and replace worn Yearly
parts >

Recorders Zero and span adjust Bimonthly Replace pens, lubricate, As required
etc. .;
i
Ion chromatograph for Run' standard when ion At least twice Oil pumps, replace Per manufactuers !
chloride and sulfate chronatograph in use daily columns, etc. instructions
analyses

Silica Monitor ' tamparison to grab sample wet B' weekly Add chemicals and verify As required e

chemical analysis proper flow

Clean sample cell and Weekly

adjust zero and span.

l
r

I
r
-
. . . . . . _ _ _ _ _ _ _ _ _ _ _ . _ _ _ _ _ _ _ _
 u

Table E-1 (continued)

Calibration Maintenance
Instrument Method Sc5edule item Schedale
f
Specific Conductivity Compare to standard cell Weekly Clean or replace cells * As requirr1

Catton Conductivity Compare to standard cell Weekly Clean or replace cells * As requirec

Replace cattort resin $3/4 exhaustloa

Sodium Monitors 10 and 100 ppb f4a Monthly Clean electrodes * When response time
increases

100 ppb fia (check buf fer flow) Weekly Replace electrodes Yearly
and compare to grab sarnple
flameless AA analysis
Dissolved Oxygen Analyzer ASIM D388 Method A Weekly Rejuvenate sensors, ~
As required
replace membrane and
Q recharge sensor
g

* Crud in Lamples will coat sensing elements necessitating r. leaning. Up to six months of operation with no detectable fouling of
the electrodes has been achieved by filtering the samples (29).

. . .
.

_ - - - . _ _ _ _ . . . - . _ _ _ . . , . , , . . . . . . , y
 APPENDIX D

ANALYSIS OF IONS ON ION EXCHANGE RESIN

CHLORIDE AND SULF /.TE CONTENT OF ANION EXCIIANGE RESIN

Summary -
'

L A sample of anion exchange resin is cluted with nitric acid, and the removed
_

chloride and sulfate in tl.s acid are determined. $

..
Eauipment ;

, 1) An approximately 3/8 inch ID by 12 inch long elution column with a resin

p support at one end.
i

- 2) Photomete>

L 3) Dionex Ion Chromatograph

p
l
Reacents

1) Water - Doubly deionized

2)' 1N HNO3- Dilute 64 ml of reagent HNO 3in sufficient deionized ' water to
imake one liter.

Procedure
;

. 1) Place 13 to 17 ml of wet swollen resin in a 25 ml graduated cylinder and

determine the tapped-cettled volume.

. 2) -Rinse the resin from the graduated cylinder into the elution column.

L
3) ' Pass d'eionized _ water down through the r.olumn .mtil the resin is packed and
L channeling has been eliminated. (NO*E: Do not allow lit [uid level to drain
p' - below the top of the resin bed.)
I
f 4)- Pass 80 ml of 1N HNO3 through the column at the rate of 5 to 10 ml/ min.
[ - Collect and measure volume of effluent in a 100 ml graduated cylinder.

- 5) iRinse acid out of column, remove resin from column and dispose of resin.

D-1

.
i
i
'

L _
. ..
 - .~ . .- . . - - .. - -. - .

6) Analyze column ef0uent for chlorldc using ASTM colorimetric procedure D-

512, Method C.

. 7) Dilute 5 ml of column effluent to 6 . with deionized water and analyze

sulfate by lon chromatography. Use at 1 m1 sample with Dionex standard
2
anion separator columns and 0.003M HCO3-/0.0024 M CO 3
/ eluent.

' Calculations
,.

. Chloride or sulfate on the resin in meq/ml (C) is given by:

.

C = (Conc. in column ef0uent,eoKdVolume of effluentu_1)

m
(Volume of resin, ml)

SODIUM, CALCIUM AND MAGNESIUM CONTENT OF CATION RESIN

Summary

A sample of cation exchange resin is eluted with nitric acid and the removed
sodium, calcinm and magnesium in the acid are determined by atomic adsorption
analysis.
'
Eauipme_nj

1) An approximately 3/8 inch ID by 12 inch long clution column with a resin

support at one end.

2) Flame atomic adsorption spectrometer.

Egag:ab.

1) Watnr - Doubly deionized ,

2) 2N HNO3- Dilute 128 ml oJ reagent lino 3in sufficient deionized water to

make 1 liter. '

Procedure .

1) Place 13 to_17 ml of wet swollen resin in a 25 ml graduated cylinder and

determ:ne the tapped-settled volume.

.2) ' Rinse the resin from the graduated cylinder into the elution column.

D-2

'
,
 _ - _ __

3) Pass deionized water down through the column until the resin is packed and
channeling has been eliminated. (NOTE: Do not allow liquid level to drain
below the top of the resin bed.)

4) Pass 100 ml of 2N HNO3 through the column at the rate of 5 to 10 ml/ min.
Collect and measure volume of effluent in a 100 ml graduated cylinder.

5) Rmse acid out of column, remove resin from column and dispose of resin.
-

6) Analyze the column effluent for sodium, calc:am and magnesium by flame
AA (ASTM D 2576 and D-1428, Method A).

Calculations

Sodium, calcium or magnesium on the resin in meq/ml (C) is given by:

C = (Conc, in column effluent, ec/l)(Volume of effluent.ml)

(Volume of resin, ml)

D-3

|
|
 - . _ _ . _ _ . _ _ __ _ _ _.._ . _ . ._ _ _ _ ..- . _ __ _ _ _ _ _ _ _

APPENDIX E .

RECOMMENDED MAINTENANCE PROGRAM

Condensate polishing systems consist of the following components that are

engineered to function within specified limits of flow, pressure, temperature, pH,
-etc.

*
I) Tanks

2) Piping'
.

3) Valves

4) Tank internal distribution systems

-5) Tank underdrain and collection system

6)__ Pun ps

'7) Instrumentation

8); ; Ion exchange resins-

When these components are not opermed within the design limits, or com,- m
arts malfunction, unit performance and water quality deteriorate. The cost of
Loperating the polisher system at less than-optimum conditions also usually escalates
markedly.

1) VALVES AND PIPING

i-
; -Recommendation
;-
L
There are many types of valves used in condensate polisher systems: globe, gate
. check, ball, and air-operated valves such as diaphragm or ball valves. Yearly
. inspection to verify integrity and proper operation is recommended. Worn parts
y , should be replaced as needcJ.- Every three to five years, valve diaphragms, gaskets,
| and rubber grommet seats should be replaced. Inspection and lubrication of valve
p operators should be performed according to manufacturers' instructions. Generally,
piping systems are satisfactory until leaks require repair or replacement.

- Discussion

Valve malfunctions are the most common problem in condensate polishing

systems. Proper inspection, repair, and replace:nent will minimize these problems.

E-1

|
, . , . - .- .- -
- .. -._ .. -. -. . .-.
 ._ . __ _. _. _ _. . .- .m _ _

-Hydrostatic testing of system components should be performed regularly to identify

leaking valves. Valve leaks can cause system performance to deteriorate.

2) PUMPS AND BLOWERS

- Recommenda tion

Blowers, centrifugal pumps and positive displacement pumps are common in

polisher systems.- Pump packing replacement as needed, and routine checks of
'
pump oil level are recomrnended. If pumps are equipped with safety relief valves,
valve operation should be checked at least every six months. Annual examination
of pump check valves and diaphragms,if used, are suggested. Centrifugal pumps ,

should be disassembled for bearing and impeller inspection every few years; the
frequency should be based on duty cycle and manufacturer's recommendation.

For systems equipped with bimyers, the blower housing, blading, and bearings
should be inspected yearly. The inlet filter should be regularly replaced or cleaned of
debris that interfere with air flow.

Proper care and lubrication of punip motors is required. Motor manufacturer -

specifications should be followed.

Discussion

Proper care and maintenance of pumps and blowers will assure long life and
trouble-free operation. Operation with worn or malfunctioning parts damages the
.

equipment and degrades performance.

3) VESSELS AND STORAGE TANKS

Recommendation

Yearly inspection of process and regeneration vessel distributors, und.erdrains and

lining are recommended. If the concentrated acid storage tank 1 reather is equipped
with a desiccating device, the drying material must be replaced periodically. The
50% caustic storage tank heating devices should be inspected annually.

Discussion - .

Mechan! cal intchrity and clean screens on vessel laterals and underdrains are
mandatory fu proper flow distribution. Manhcle cover removal will be needed for
inspection of the vessel lining. If the vessels are equipped with sight glasses as
recommended in Section 3, the required inspection probably can be performed
without vessel entry. Damaged or clogged laterals and underdrains, and damaged
clinings will qie vessel entry for repair. After the cleaning or repair of laterals or
underdrains, the ' components should be tested for proper flow distribution.

E-2

.-
 _ . _ _ _ _ . ._ _ . _.. . . . _ _ _ . _ . _ . . _ . _ . . _ _ _ _ . . _ . _ _ _ .

The 50% caustic storage tank needs to be kept above the 54 F (12.2 C) freezing point.
The tanks generally are equipped with heaters to maintain the proper temperature.

4) INSTRUMENT CALIBRATION AND MAINTENANCE

Recommendation

*
Ensure that all instruments are valved into system, and tl'at sample flowrates and
temperatures are properly controlled. Recommended individual instrument
. calibrations and maintenance are given in Table E-1.

Discussion

The operator needs accurate and reliable instruments to optimize polisher

operation. The highest quality instruments available will not give reliable results
without proper calibration and maintenance. Once records of indiv.idual
instrument calibration and maintenance requirements are accumulated, a basis for
changing schedules recommended in Table E-1 and replacing problem prone
instruments is available.

..

i.

E-3

'
-
.

. 1
 '

_
.

-|

APPENDIX F !

CRUSH STRFNGTH TEST PROCEDURE (1)

INTRODUCTION
:

"
The ability of resin to resist fracture due to pressure drop across the resin bed during
service or during transfer operations shall be determined by measuring the amount
. of force required to crush individual resin beads when placed between two parallel
planes. This test shall be performed on batches of. cation resin in the hydrogen form
and anion resin in the hydroxide form, using the procedure outlined below.

PROCEDURE

-1) Soak resin in distilled water for at least one hour immediately prior to
screening and testing.

2); Wet screen each batch of resin and collect several hundred beads which pass
through a No. 20 U.S. Standard sieve series screen but are retained on a No. 30 -
screen. Store the resin in distilled water until ready for testing.

3) Randomly select beads from the separated 20- to 30-mesh fraction. Measure the
force rcquired to fracture each individual bead when placed between two
parallel planes. A convenient instrument for measuring the force applied is a -

Chatillon scale, Model DPP-1KG. The test shall be conducted with a water
dronlet adhering to the bead.

PRESENTATION OF RESULTS
'
' Results from measurements on each batch of anion beads or cation beads shall be
c
averaged separately and shall meet these specifications. The average force required
, to fracture 60 individual beads shall be greater than 350 grams / bead. At least 60
_

g beads shall be tested and all beads tested shall be included in the average. Ninety-
L five percent (95%) of the beads tested from each batch shall have a crush strength of
o
u >200 grams / bead.

REFERENCES

1. | Johanneson, O., " General Electric Purchase Specification far Ion Exchange
Resins," April 9,1975 (21A8844 Rev. 0).

F-1

|
|
_ _ - . -
_ _ - _ _ _ - - _ -
 -. _.-.-.~

APPENDIX G y
- !

DYNAMIC CAPACITY TEST PROCEDURE

, 4

INTRODUCTION

Variations can occur in resin performance at flow rates used for condensate
_

treatment which are not apparent from the normally performed quality assurance
'
tests. This test of a mixed bed of hydrogen form cation resin and hydroxide form
anion resin indicates relative performr.nce at flowing conditions.
*
. PROCEDURE

1)- Mcasure sufficient cation and anion resin at 1:1 equivalence ratio
(approximately 2 cation te 3 anion by volume) to provide a 3 ft, deep mixed bed
in a column >3 in ID.

2) Load test column and air mix the resins.

3) Circulate demineralized water, which contains 10 ppm Nacl and sufficient

NII 0H to adjust pH to 9.0 through the mixed bed at 50 gpm/ft2 (2040
4
2
liters /m -min) with a centrifugal pump.

- 4) Measure the bed effluent concentrations of sodium and chloride at tirnes

corresponaing to 40,50 and 60% exhaustion of the resins (cation to sodium and
anion to chloride). For example, the time to exhaust 40% of cation resin at 50
2_
gpm/ft , and 10 ppm is given by: .

'

t (min) = 2.87 (cation volume, ml) (capacity *, meq/ml)(40%)

,
(Bed cross sectional area, cm') (100 ppm)

~ 5) - Calculate percent leakage as follows:

Leakage (%) = 100 (Effluent concentracion, ppm)

,
_ Influent concentration, ppm

* Measured hydrogen and hydroxide capacity of new resin used

for test.

'

|
!

L G-1

L -.- - .- __- - ._ _