Troubleshooting guide

Industrial Water Treatment

resins
 Troubleshooting guide

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Troubleshooting guide
2 July 2010
 Type of application

 Industrial Softeners
 Primary Cation Exchanger
 Primary Anion Exchanger
 Mixed Bed Demineralizer

End

Troubleshooting guide
3 July 2010
 Industrial Softeners

 Reduced Throughput
 Poor Effluent Quality
 High Pressure Drop
 Low Pressure Drop

Troubleshooting guide
4 July 2010
 Industrial Softeners –
Reduced Throughput (1)
Increased ionic loading
Channeling, poor distribution
■ Suspended solids loading
■ Broken or clogged distributors
■ Low flow
Premature break
Regenerant concentration and quantity
Resin loss
■ Excessive backwash
■ Underdrain failure
■ De-cross linked resin
■ Flotation by dissolved gas
■ Normal bead attrition
Troubleshooting guide
5 July 2010
Check influent water hardness
Increase regenerant
Add capacity
Check backwash; extend if needed
Repair
Maintain minimum flow
Check previous run throughput
If normal regenerant does not restore capacity, double regenerate
Adjust end point
Check metering pumps, eductors, piping, etc.
Regenerant dosage
Do brine elution study (brine curve)
Check dilution flows, time settings
Apply correct amount at correct concentrations
Check temperature and flowrate
Check and repair (resin trap?)
See “oxidation”
Effluent flow control
Top off
 Industrial Softeners –
Reduced Throughput (2)
Resin age Up to 5% / yr loss in capacity considered normal
Analyze resin to determine remaining useful life
Resin oxidation
Presence of oxidants (chlorine) and oxygen Chemical pre-treatment of feed water/activated carbon filter
in presence of catalysts (iron) causes Replace resin when moisture
de-cross linking which content exceeds 65%
reduces wet volume capacity (eventually high Δ P)

Resin fouling
■ Iron, manganese, aluminium fouling Check water supply (analysis)
and precipitates Check backwash
Check regenerant chemicals for contaminants (analysis)
Clean resin by air-scour and backwash and chemically if required
■ Microbiological fouling Clean resin with appropriate cleaner (compatible with resin)

Excessive rinsing Check end-of-rinse set points

Readjust rinse time to suit
Check for fouling (see above)

Troubleshooting guide
6 July 2010
 Industrial Softeners –
Poor Effluent Quality
Note: All of the items listed above for “Reduced Throughput” should also be checked regarding poor effluent quality.

Leaky valve Check bed sample vs. discharge pipe sample (before and after valving);
special caution on backwash inlet valve
Check limit stops on valve operators
Check air pressure on pneumatic valves
Check sealing gaskets on multiports
Check for physical damage due to water hammer
Flow rates too high
■ Insufficient reaction time (kinetics) Reduce flow

Flow rates too low

■ Poor distribution, channeling Place one or more units in standby to increase flowrate
Recycle treated water to inlet

Resin fouling See “Resin fouling” above under “Reduced Throughput”

For counter-current regeneration: Check resin level and add resin as needed
loss of inert (inactive) resin allows resin
migration which, in turn, causes high leakage

In counter-current regeneration, Check resin level and add resin as needed

it is important to use soft
water for regenerant dilution
and displacement rinse

Troubleshooting guide
7 July 2010
 Industrial Softeners –
High Pressure Drop
Bed compaction Check flow and temperature for sufficient backwash
Air or mechanical scour prior to backwash

Resin fines Remove with backwash

Cation resin de-crosslink Analyze resin and replace if necessary

Lower water temperature Δ P increases with higher water viscosity at lower temperature

Increased flow rate Δ P increases with flow (do not exceed specified ΔP)

Valve partially closed Check and adjust all valves

Internal distributor blockage

■ With resin, iron, debris Inspect strainers and clean
Repair / clean distributors
Flow rates too high
■ Insufficient reaction time (kinetics) Reduce flow

Plugged underdrain
■ Resin or subfill in collectors, outlet strainers Inspect internals

Increased suspended solids loading in influent Mid-cycle backwash

Resin fouling See “Resin fouling” above under “Reduced Throughput”
Troubleshooting guide
8 July 2010
 Industrial Softeners –
Low Pressure Drop
Note: Low pressure drop is not necessarily a problem in itself; however, it may be a symptom of a problem.

Leaky valve Check bed sample vs. discharge

Reduced flow Δ P decreases with flow

Increased temperature Lower viscosity—check backwash rate at higher temperature

Resin loss, reduced bed depth

■ Underdrain failure Check for loss to sewer during backwash and rinses
■ Resin attrition Inspect and repair
■ Resin loss See “Resin loss” above under “Reduced Throughput”

Troubleshooting guide
9 July 2010
 Primary Cation Exchanger

 Reduced Throughput
 Poor Effluent Quality
 High Pressure Drop
 Low Pressure Drop

Troubleshooting guide
10 July 2010
 Primary Cation Exchanger
Reduced Throughput (1)
Increased ionic loading
Channeling, poor distribution
■ Suspended solids loading
■ Broken or clogged distributors
■ Low flow
Premature break
Regenerant concentration and quantity
Resin loss
■ Excessive backwash
■ Underdrain failure
■ De-crosslinked resin
■ Flotation by dissolved gas
■ Normal bead attrition
Troubleshooting guide
11 July 2010
Check influent water analysis
Increase regenerant
Add capacity
Check backwash; extend if needed
Repair
Maintain minimum flow
Check previous run throughput
If normal regeneration does not restore capacity, double regenerate
Adjust end point
Check metering pumps, eductors, piping, etc.
Regenerant dosage
Check dilution flows, time settings
Apply correct amount at correct concentrations
Check temperature and flowrate
Check and repair (resin trap?)
Effluent flow control
Top off
 Primary Cation Exchanger
Reduced Throughput (2)
Resin age Up to 5% / yr loss in capacity considered normal
Analyze resin to determine remaining useful life
Resin oxidation
■ Presence of oxidants (chlorine) and oxygen in Chemical pretreatment of feedwater/activated carbon filter
presence of iron (catalyst) causes de-crosslinking Replace resin when moisture content exceeds 65%
which reduces wet volume capacity
(eventually high ΔP)

Resin fouling
■ Calcium sulfate, iron, manganese, aluminium Check water supply
fouling and precipitates for contaminants Check backwash
Check regenerant chemicals
Clean resin by air-scour and backwash and chemically if
required
■ Microbiological fouling Clean resin with appropriate cleaner (compatible with
resin)

Excessive rinsing Check end-of-rinse set points

Readjust rinse time to suit
Check for fouling (see above)

Troubleshooting guide
12 July 2010
 Primary Cation Exchanger
Poor Effluent Quality (1)
Note: All of the items listed above for “Reduced Throughput” should also be checked regarding poor effluent quality.

Calcium sulfate precipitation

■ Calcium in treated water should be zero Check resin
If severely fouled, replace resin
If moderately fouled, clean resin with an HCl soak (caution—check materials of
construction for compatibility with HCl)
Check influent water calcium concentration (% of total cations)
Check and adjust acid concentration (stepwise regeneration) and flowrate
Presence of calcium phosphate or Check pretreatment
other complexes in feedwater

Notes: For weak acid cation exchangers regenerated with H2SO4, acid strength should not exceed 0.8 % with a flowrate of 2 gpm/ft3.
In countercurrent regeneration, it is important to use decationized or demineralized water for regenerant dilution and displacement rinse.
Once sulfuric acid injection is started, never stop flow. If acid injection must be interrupted, stop concentrated acid flow but let dilution flow run until all
acid is displaced.

Troubleshooting guide
13 July 2010
 Primary Cation Exchanger
Poor Effluent Quality (2)
Excess sodium in treated water ran past breakpoint Check and adjust set points
Check regenerant dosage and quality
Investigate conversion to upflow or hydrochloric acid regeneration
Leaky valve Check bed sample vs discharge pipe sample (before and after valving); special
caution on backwash inlet valve
Check limit stops on valve operators
Check air pressure on pneumatic valves
Check sealing gaskets on multiports
Check for physical damage due to water hammer
Flow rates too high
■ Insufficient reaction time Reduce flow
(kinetics)
Flow rates too low
■ Poor distribution channeling Place one or more units in standby to increase flowrate
Recycle treated water to inlet
Resin fouling See “Resin fouling” above under “Reduced Throughput”

For counter-current regeneration, a loss of Check resin level at exhaustion and add resin as needed
inert (inactive) resin allows resin migration
which, in turn, causes high leakage

Troubleshooting guide
14 July 2010
 Primary Cation Exchanger
High Pressure Drop
Bed compaction Check flow and temperature for sufficient backwash
Air or mechanical scour prior to backwash

Resin fines Remove with backwash

Cation resin de-crosslink Analyze resin and replace if necessary

Lower water temperature Δ P increases with higher viscosity at lower temperature

Increased flow rate Δ P increases with flow (do not exceed specified Δ P)

Valve partially closed Check and adjust all valves

Internal distributor blockage

■ With resin, iron, debris Inspect strainers and clean
Repair / clean distributors
Plugged underdrain
■ Resin or subfill in collectors Inspect internals or outlet strainers

Increased suspended solids loading Mid-cycle backwash

Check filtration ahead of demineralizer

Resin fouling See “Resin fouling” above

Troubleshooting guide
15 July 2010
 Primary Cation Exchanger
Low Pressure Drop
NOTE: Low pressure drop is not necessarily a problem in itself; however, it may be a symptom of a problem.

Reduced flow Δ P decreases with flow (normal)

Increased temperature Lower viscosity

Check backwash rate at higher temperature

Resin loss, reduced bed depth

■ Underdrain failure Check for loss to sewer during backwash and rinses
■ Resin attrition Inspect and repair
■ Resin loss See “Resin loss” above under “Reduced Throughput”

Troubleshooting guide
16 July 2010
 Primary Anion Exchanger

 Reduced Throughput
 Poor Effluent Quality
 High Pressure Drop
 Low Pressure Drop

Troubleshooting guide
17 July 2010
 Primary Anion Exchanger
Reduded Throughput (1)
Increased ionic loading Check influent water analysis
Increase regenerant
Add capacity
Channeling, poor distribution
■ Suspended solids loading Check backwash, extend if needed
■ Broken or clogged distributors Repair
■ Low flow Maintain minimum flow

Premature break Check previous run throughput

If normal regeneration does not restore capacity, double regenerate
Adjust end point

Regenerant concentration and quantity Check metering pumps, eductors, piping, etc.
Regenerant dosage
Check dilution flows, time settings
Apply correct amount at correct concentrations

If degasser (decarbonator) is used Check CO2 at the outlet of the clearwell: should be less than 5 ppm.
If not:
- Check air filter on blower; replace if dirty
- Inspect packing (rings) in column. If dirty or slimed, replace packing.

Troubleshooting guide
18 July 2010
 Primary Anion Exchanger
Reduded Throughput (2)
Resin loss
■ Excessive backwash Check temperature and flowrate
■ Underdrain failure Check and repair (resin trap?)
■ De-crosslinked resin See “oxidation”
■ Flotation by dissolved gas Effluent flow control
■ Normal bead attrition Topoff
Resin age Up to 5% / yr loss in capacity considered normal
Analyze resin to determine remaining useful life
Resin degradation
■ Resin exposed to excessive Do not exceed 120°F anytime for type I styrenic strong
base anion resins
temperature Do not exceed 95°F anytime for type II styrenic or type I
acrylic strong base anion resins
Excessive rinsing
■ Organic fouling (organics tend to hold on to Partial restoration of resin with a brine squeeze
sodium as they contain weak sites which Analyze resin for strong base capacity and replace resin if
necessary
retain sodium) Incorporate routine brine squeezes into operation of plant
In the case of weak base anions, consider regeneration with ammonia
Recycle rinse water to reduce water usage
Adjust rinse end-point
Check caustic concentration (higher concentration requires more rinse water)
For high TOC waters, consider the installation of an organic trap

Troubleshooting guide
19 July 2010
 Primary Anion Exchanger
Reduded Throughput (3)
Presence of cation resin in anion bed
and
Resin fouling
■ Silica precipitation
portion of
If degasser (decarbonator) is used
Troubleshooting guide
20 July 2010
Analyze resin
Check for presence of cation resin in anion bed
Identify cause of presence of cation resin (leaky or broken strainer or lateral)
repair
Lower caustic strength (2.5% suggested)
Thoroughfare regeneration (strong base anion/weak base anion): dump first
strong base eluate before feeding residual caustic to WBA resin
Check air filter on blower; replace if dirty, damaged or missing
 Primary Anion Exchanger
Poor Effluent Quality (1)
Note: All of the items listed above for “Reduced Throughput” should also be checked regarding poor effluent quality.

High conductivity or pH in treated water

■ Ran past cation breakpoint Check cation effluent
If cation effluent is within acceptable range, check anion resin
Chemical precipitation
■ Hardness in regenerant dilution Check for calcium and magnesium in cation and anion
effluent
and / or rinse waters Insure that dilution and rinse waters are hardness-free

Hardness in treated water Check cation performance

Check for hardness in all waters used for regeneration to eliminate precipitates

Chloride or silica in treated water Check regenerant specs for chloride and silica content (mercury cell or rayon
grades of caustic are acceptable)
Check for leaking regenerant (caustic) valve

Troubleshooting guide
21 July 2010
 Primary Anion Exchanger
Poor Effluent Quality (2)
Note: All of the items listed above for “Reduced Throughput” should also be checked regarding poor effluent quality.

Leaky valve Check bed sample vs discharge pipe sample (before and after valving); special
caution on backwash inlet valve
Check limit stops on valve operators
Check air pressure on pneumatic valves
Check sealing gaskets on multiports
Check for physical damage due to water hammer
Flow rates too high
■ Insufficient reaction time (kinetics) Reduce flow

Flow rates too low

■ Poor distribution channeling Place one or more units in standby to increase flowrate
Recycle treated water to inlet

Resin fouling See “Resin fouling” above under “Reduced Throughput”

For counter-current regeneration, a loss of inert Check resin level at exhaustion and add resin as needed
(inactive) resin allows resin migration
which, in turn, causes high leakage

In counter-current regeneration, it is
important to use demineralized water for
caustic dilution and displacement rinse

Troubleshooting guide
22 July 2010
 Primary Anion Exchanger
High Pressure Drop
Bed compaction Check flow and temperature for sufficient backwash
Air or mechanical scour prior to backwash

Resin fines Remove with backwash

Lower water temperature Δ P increases with higher viscosity at lower temperature

Increased flow rate Δ P increases with flow (do not exceed specified Δ P)

Valve partially closed Check and adjust all valves

Internal distributor blockage

■ With resin, iron, debris Inspect strainers and clean
Repair / clean distributors
Plugged underdrain
■ Resin or subfill in collectors or outlet strainers Inspect internals

Resin fouling See “Resin fouling” above under “Reduced Throughput”

Troubleshooting guide
23 July 2010
 Primary Anion Exchanger
Low Pressure Drop
NOTE: Low pressure drop is not necessarily a problem in itself; however, it may be a symptom of a problem.

Reduced flow Δ P decreases with flow

Increased temperature Lower viscosity

Check wash rate at higher temperature

Resin loss, reduced bed depth

■ Underdrain failure Check for loss to sewer during backwash and rinses
■ Resin attrition Inspect and repair
■ Resin loss See “Resin loss” above under “Reduced Throughput”

Troubleshooting guide
24 July 2010
 Mixed Bed Demineralizer

 Reduced Throughput / Poor Effluent Qu

ality

Troubleshooting guide
25 July 2010
 Mixed Bed Demineralizer
Reduced Throughput / Poor Effluent Quality (1)
NOTE: Most comments for cation and anion apply to mixed-bed demineralizers and for best performance always use mixed-bed grade resin.

Poor primary exchanger performance Troubleshoot primary cation and anion exchangers

Poor separation of mixed bed in first step of regeneration

Check flowrates and temperature of backwash water
Check for proper resin vs mid-collector interface location
Insure use of mixed-bed grade resin
Interface too low because of loss of cation resin
Add cation resin

Interface too high because of separation and anion trapped within cation bed
Check flowrates and temperature of backwash water
Correct flowrates

Interface too high because of overcharging of cation resin

Remove appropriate amount of cation resin

Cross contamination Result of poor separation of the cation and anion resins; improper interface
location due to loss or overcharging of cation resin

Acid in the anion zone which causes SO4 leakage and early anion exhaustion
Insure adequate blocking flow

Troubleshooting guide
26 July 2010
 Mixed Bed Demineralizer
Reduced Throughput / Poor Effluent Quality (2)
Caustic in the cation zone which causes Na leakage and early cation exhaustion
Insure adequate blocking flow

Insufficient displacement rinse which results in resin cross- contamination and high effluent conductivity
Extend displacement rinse to achieve acceptable conductivity

Insufficient mixing after regeneration step caused by insufficient air flow

Check and adjust air flow

Improper drain down prior to air mix Check water level prior to air mix
Adjust setting for water level

Fluidization and reseparation of the bed during refill due to excess flowrate
Perform a slow fill through the caustic distributor followed by a fast fill
throughthe service inlet

Excessive Final Rinse Poor resin separation (see above)

Cross contamination (see above)
Premature silica break
■ Silica precipitation due to contact with acid Start acid injection 20 minutes after start of caustic
injection

Troubleshooting guide
27 July 2010