Oin Ops Chem 016 Filter Media and Resing Checks

(For Internal Circulation)
COS-ISO-00-OIN/OPS/CHEM/016
Rev. No. : 0 March 2005
OPERATION INFORMATION NOTE
Manual on Quality Checks &

Treatment for Filter Media and
Ion Exchange Resins during
Overhaul
CORPORATE OPERATION SERVICES
National Thermal Power Corporation Ltd.
NATIONAL THERMAL POWER CORPORATION LTD.

OPERATION & MAINTENANCE FORMAL DOCUMENTATION SYSTEM
OPERATION INFORMATION NOTE : COS-ISO-00-OIN/OPS/CHEM/016
Rev. No.: 0
Date : March, 2005
Manual on Quality Checks &

Treatment for Filter Media and
Ion Exchange Resins during
Overhaul
Approved for
Implementation by ..
E. D. (OS)
Date: ..
Enquiries to: Head of Corp. Operation Services
Manual on Quality Checks & Treatment for Filter Media and Ion
Exchange Resins during Overhaul
INDEX
S.NO.
DESCRIPTION
PAGE NO.
1.
Introduction
2.
Superseded Documents
3.
Quality checks for filter media, activated Carbon, &

Ion exchange resins and media replacement.
4.
Maintenance & Treatment of filter media and ACF
5.
Fouling & degradation of ion exchange resins and

Estimation of organic fouling of anion resin
6.
Treatment of ion exchange resins
10
7.
Measurement of bed depth and removal of fines
13
8.
Sampling of ion exchange resins
15
9.
Review
20
Annexures
Formats for reporting various activities
21
Page - 1
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Manual on Quality Checks & Treatment for Filter Media and Ion Exchange Resins during Overhaul
Manual on Quality Checks & Treatment for Filter Media and Ion Exchange
Resins during Overhaul
1.0
INTRODUCTION
Very high purity water is required for cycle make up in high pressure boilers. This high
purity make up water is produced from water demineralization plant through the process
of demineralization using different ion exchange resins. In order for the ion exchangers to
function properly i.e., produce the desired quality and quantity of water, the water
pretreatment plant should function properly particularly the filtration units and the ion
exchange resins be maintained in excellent condition. Therefore regular quality checks
for filter media and ion exchange resins are mandatory in order to get the highly pure
cycle make up water.
Condensate polishing units and softening plant using ion exchange also contain different
ion exchange resins. For these plants also the resin should be maintained in excellent
condition for getting desired effluent quality and quantity which again need regular
quality checks for ion exchange resins.
This manual describes the various quality checks to be performed for filter media,
activated carbon, and ion exchange resins during an overhaul and the method of treatment
for restoring their lost capacities in the event of deterioration. The manual also covers
sampling and estimation of fouling & degradation of filter media/ion exchange resins and
organic fouling of anion exchange resins in particular and their remedial measures.
Formats for recording various activities are also covered in this manual.
This manual will be of immense help to power plant chemists for maintaining the filter
media and ion exchange resins in their water treatment plants.
2.0
SUPERSEDED DOCUMENTS
Nil
Page - 2
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3.0
QUALITY CHECKS FOR FILTER MEDIA, ACTIVATED CARBON, & ION

EXCHANGE RESINS AND MEDIA REPLACEMENT
3.1
PRESSURE FILTER AND GRAVITY FILTER
3.1.1
THE FILTERS SHOULD BE CHECKED FOR THE FOLLOWING
3.1.1.1 Filter media bed depth should be checked for loss of media. Top up if required.
3.1.1.2 Mud balls and lumps of filter media.
3.1.1.3 Channeling in the bed. Filter media shall be removed for screening and grading.
3.1.1.4 Media fouling (bio-fouling).
3.1.1.5 Check for the presence of Fines. Remove fines if required.
3.1.2
MEDIA REPLACEMENT
3.1.2.1 The pressure filter/gravity filters (sand filters) should be replaced in case of deterioration
in design effluent quality, output, or physical degradation, which are not restored even
after the treatment.
3.1.2.2 Following tests should be carried out for checking physical degradation:
Effective size.
Uniformity coefficient.
Specific gravity.
3.1.2.3 Bed capacity reduces to 60% w.r.t original capacity.

3.1.2.4 Bed outlet parameters deviate to 20% w.r.t original parameters.
3.1.2.5 Bed loss of head increases by 20% w.r.t original value.
3.2
ACTIVATED CARBON FILTER
3.2.1
THE FILTERS SHOULD BE CHECKED FOR THE FOLLOWING:
3.2.1.1 Filter media bed depth should be checked for loss of media. Top up if required.
3.2.1.2 Mud balls and lumps of filter media.
3.2.1.3 Channeling in the bed. Filter media shall be removed for screening and grading.
3.2.1.4 Media fouling (bio-fouling).
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3.2.2
MEDIA REPLACEMENT
3.2.2.1 The activated carbon beds should be considered for replacement in case of deterioration
in design effluent quality, output, loss of chlorine removal ability, biological fouling, iron
fouling, or physical degradation, which are not restored even after the treatment.
3.2.2.2 Following tests should be carried out for checking physical degradation:
Particle size distribution.

Effective size.
Uniformity coefficient.
Apparent density.
Moisture content.
Abrasion resistance.
Water soluble ash.
Iodine value.
3.2.2.3 Bed capacity reduces to 60% w.r.t original capacity.

3.2.2.4 Bed outlet parameters deviate to 30% w.r.t original parameters.
3.2.2.5 Bed differential pressure increases by 30% w.r.t the original value.
3.2.2.6 Bed backwash flow reduces to 25% w.r.t original flow.
3.2.2.7 Residual chlorine is detected at the outlet.
3.3
ION EXCHANGE RESINS (DM PLANT, SOFTENER, CPU)
3.3.1
THE ION EXCHANGE RESINS BEDS SHOULD BE CHECKED FOR THE

FOLLOWINGS:
3.3.1.1 Ion exchange vessels internal lining integrity.

3.3.1.2 Distributors/ collectors should be checked for tightness and broken, bent, cracked, or
corroded components.
3.3.1.3 Channeling in the bed.
3.3.1.4 Resin bed depth should be checked for loss of resin. Top up if required.
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3.3.1.6 Dilution water should be run through regenerant distributor laterals to check for uniform
flow.
3.3.1.7 Mixed bed should be checked for clear separation of cation and anion resins.
3.3.1.8 Fouling of resins. Appropriate treatment should be given to remove fouling.
3.3.2
RESIN REPLACEMENT
3.3.2.1 Due to oxidation, degradation, and fouling ion exchange resins should be replaced
periodically. Minimum expected life span of an anion resin is 3-5 years and that of cation
resin 10-15 years.
3.3.2.2 When the desired effluent quality or quantity can no longer be achieved or restored via
alkaline brine treatment/other chemical treatments, the resin replacement should be
considered.
3.3.2.3 Resins may be replaced when the capacity has declined to 65-70% of the original
capacity and improvement is not possible by other means. For anion resin this refers to
strong base capacity.
3.3.2.4 Bed chemical consumption increases to 25% w.r.t the original consumption.
3.3.2.5 Bed pressure drop increases to 30% w.r.t original value.
3.3.2.6 The following tests should be conducted to check the condition of the resins:
Visual appearance.
Odour.
Moisture content.
Particle size distribution.
Mixed bed resin separation.
Ash content and metals.
Organic fouling of Anion resins.
Column performance.
Total exchange capacity.
Salt splitting capacity (in case of strong resins).
Kinetics- Mass transfer coefficient (MTC).
Fine content (passing 50-mesh i.e., 0.3 mm sieve opening)- 1% maximum in case of
SAC and 3% maximum in case of WAC and anion resins.
Page - 5
Rev. No.: 0
Note: Use formats in Annexures for recording the activities performed.
4.0
MAINTENANCE & TREATMENT OF FILTER MEDIA AND ACF
4.1
SAND FILTERS
4.1.1
MAINTENANCE
4.1.1.1 Filtration systems in makeup water treatment operations usually do not require extensive
maintenance.
4.1.1.2 Conventional sand filters require the least maintenance. Dual media, mixed media, and
activated carbon beds follow in order of maintenance intensity.
4.1.1.3 The visual inspection and core sampling provides an indication of media condition at
various elevations in the bed. Core samples are necessary after a noticeable bed upset or
when plugging appears to be a problem.
4.1.1.4 Routine core sample analysis every 3-year is generally desirable.
4.1.2
CHEMICAL TREATMENT
When sand gets coated with material that is difficult to remove by normal wash, the filter
is washed with NaOH (10 kg/m2 area of the bed) or bleaching powder (20 kg/m2 area of
the bed).
4.1.3
CRACKING OF SAND BED

This occurs mostly when the water is lowered below the surface of sand and may also
arise due to cementing of the grains by some material in the influent water. The
vulnerable portion is near the filter walls. Since the sand is drawn away from the walls,
the rate of flow increases through such cracks allowing a heavier deposit of solids at
these points, which in turn intensifies the forces compacting the sand until a dense mass
is formed. This creates a dead area resulting in an unequal distribution of the wash water.
This can be overcome by removing the clogged sand.
4.1.4
MUD BALLS
The general building up of materials not removed in back wash causes the formation of
mud balls. These accumulate at or near surface and in course of time clog the entire area.
Proper clarification of influent water can considerably reduce the mud ball formation.
Surface wash or shoveling at intervals helps to reduce mud ball formation. Extended
compressed air scouring also effectively decreases the mud ball concentration.
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Page - 7
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4.1.5
SLIME GROWTH
When slime growth is noticed on filters, the bed is cleaned in the normal way and the
water is lowered to the level of sand bed. Common salt is distributed evenly over the
surface of the sand using 7 kg/m2 of the filter area. Wash water valve is opened till water
rises about 15 cm above the sand level. The water is allowed to remain for 2 hours to
dissolve the salt and then lowered to the bed level to be retained for 24 hours. The bed is
then thoroughly back washed. If procedure does not produce effective results, it may be
necessary to replace the media.
4.2
ACTIVATED CARBON FILTERS
4.2.1
MAINTENANCE
The only major maintenance of carbon filters is to address biofouling of the bed and
replacement of the media.
If biological fouling is found to be a significant problem, the bed may be periodically
steam cleaned.
4.2.2
STEAM CLEANING PROCEDURE

Backwash, drain, and vent the bed.
Upflow steam (low pressure at 1-2 kg/cm 2) to heat the carbon and maintain
temperature for 1 to 2 hours.
Cool the bed by slowly refilling with cold water. Unit should be properly vented to
avoid generation of a vacuum.
Backwash the bed for 15 minutes to remove any fines, suspended solids, and dead
biological matter.
NOTE:
1.
For steam cleaning separate arrangement is to be made as filters generally have

PVC nozzles and epoxy coating which may damage due to introduction of steam.
2.
Steam may result in 10-20% carbon loss during cleaning due to the formation of
fines which are lost during subsequent backwashing. Hot water exposure has been
reported to be preferred over steam sterilization for removing biofilms from
activated carbon. It is most effective when operated in the backflush mode.
Page - 8
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4.2.3
HYDROCHLORIC ACID AND CAUSTIC CLEANING
Biological fouling can be reduced by cleaning with acidic or alkaline solutions.

Cleaning with HCl (5%) followed by neutralization with an alkali can be performed
in 2 to 3 hours. Compatibility with the use of HCl to be ensured for filtration unit.
Cleaning with a 5% caustic solution requires 10 to 15 hours due to excessive time

required to rinse out the residual caustic.
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5.0
FOULING & DEGRADATION OF ION EXCHANGE RESINS AND

ESTIMATION OF ORGANIC FOULING OF ANION RESIN
5.1
DETECTION OF FOULING AND DEGRADATION OF ION EXCHANGE

RESINS
Resins used in demineralization system may deteriorate due to many factors including
chemical attack, fouling by organic and inorganic materials, mishandling, or the effects of
aging. Detection of degradation of fouling may be important in determining the cause of
poor demineralizer performance.
S.NO.
PROPERTY
RESULT
POSSIBLE INDICATION
1.
Visual appearance
Unusual colour or
precipitates.
Coating on beads from foulants or improper

regeneration.
Pieces/fragments
present.
Unusual odour.
Physical degradation.
2.
Odour
3.
Moisture
Higher than expected

(>10% above).
Lower than expected.
4.
Smaller sizes than

expected.
Larger sizes than
expected.
Poor separation.
5.
Mixed bed resin

separation
6.
Ash content and

metals
Higher than expected.
7.
Organic fouling of
anion resins
Column
performance
Kinetics
Moderate to severe.
8.
9.
5.2
Particle size
distribution
Poorer than expected.

Poorer than expected.
Fouling of resin by oil, solvents etc., or

biological activity.
Degradation of resin causing decrosslinking.
Fouling of resin by heavy materials, such as
metal oxides.
Physical degradation or non-representative
sample.
Loss of smaller beads by backwash or through
strainers.
Resin may be fouled.
Particle size distribution of beads may be
incorrect.
Fouling or resin by expected metal oxides or
silica (from corrosion products, influent water,
or regenerants).
Presence of sufficient organic fouling to affect
performance.
Degradation or fouling sufficient to affect
performance.
Degradation or fouling sufficient to affect
performance.
ESTIMATION OF ORGANIC FOULLING OF ANION EXCHANGE RESINS

One of the major factors in the unsatisfactory performance of anion exchange resins is
their fouling by organic material. Knowledge of the degree of fouling can be used to
assess the condition of the resin and may indicate the need for pretreatment of the
influent, remedial cleaning procedures, or resin replacement.
Page - 10
Rev. No.: 0
A sample of anion exchange resin is contacted with a sodium chloride/sodium hydroxide
solution at an elevated temperature. After a specified contact time, the concentration of
organic material in the aqueous phase is measured as total organic carbon (TOC).
5.3
PROCEDURE
Weigh three 2.0 g portions of the sample into 125 ml Erlenmeyer flasks. Add 20 ml of
sodium chloride/sodium hydroxide solution (100 g NaCl and 10 g NaOH per litre). Cover
the flask with a small inverted beaker. Place flasks in a water bath at 90 + 20C for 1 h.
After 1 h of heating, remove the flasks from the water bath. Add 50 ml of water and cool
to room temperature. Filter the supernatant solution through a sintered glass funnel and
neutralize to pH 3 to 5 by drop wise addition of sulphuric acid (1+49). Dilute to 100 ml in
a volumetric flask.
Determine the total organic content in mg/l of each of the three replicates using TOC
instrument by standard test method or in accordance with manufacturer instructions. Run
a blank test also containing all regents and calibrate using standards containing 20 ml of
sodium chloride/sodium hydroxide solution per 100 ml total volume with pH adjustment
with sulphuric acid.
Calculate the organic carbon removed by averaging the values and dividing by 20 to give
the mg of carbon per g of wet resin.
Organic carbon removed
(mg C/g wet resin)
Degree of organic fouling
0 to 1
1 to 2
2 to 5
5 to 10
Greater than 10
Very low
low
moderate
heavy
severe
NOTE
For a more rapid, but less reliable evaluation of the resin, the caustic-brine extract from
the above procedure may be judged by colour rather than by TOC measurement: the
darker the colour, the heavier the organic fouling. The colourless foulants such as
detergents or synthetic polyelctrolytes will not be detected.
The formats in Annexures may be used for recording the activities performed.
Page - 11
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6.0
TREATMENT OF ION EXCHANGE RESINS
6.1
CHEMICAL CLEANING OF FOULED RESINS

There are various formulations and procedures for chemically cleaning the fouled ion
exchange resins. The following table summarizes foulants and the cleaning solvent.
6.1.1
S.NO.
FOULANT
CLEANING SOLVENT
1.
Organics
Alkaline brine (or hypochlorite)
2.
Oil
Surfactants
3.
Hardness, Iron
HCl
4.
Silica
Caustic or Alkaline brine
5.
Biological
(cation)
growth Alkaline brine or caustic (or hypochlorite)
ALKALINE BRINE CLEANING
6.1.1.1 This cleaning is generally used to remove organics and other foulants from anion resins
and biological growth in cation resin. The cleaning solution contains 10-15% by wt.
Solution of brine and a 0.25-2% solution of caustic soda. If strong acid cation resin is to
be cleaned, the alkaline brine wash shall be preceded by a 10% brine wash to purge acid
and hardness from the bed. The quantity of alkaline solution depends on the severity of
fouling but a 3-bed volume is generally used.
6.1.1.2 PROCEDURE
Backwash at normal rate until suspended solids and fines are removed from the resin
bed.
Air lance and backwash for 20-30 minutes to further condition the bed.
Drain water level down to about 5 cm above the top of the resin bed.
Inject one bed volume of the brine/caustic solution at normal regenerant flow rate.
For better results temperatures of 35-490C can be used (For type-II strong base anion
resin the temperature should not exceed 350C and for type-I strong base anion resin
temperatures up to 490C can be used).
Displace the first bed volume with a second at the regenerant flow rate.
Page - 12
Rev. No.: 0
Allow to soak for 8-hours or overnight with intermittent mixing by air scouring.
Inject the third bed volume of brine solution at regenerant flow rate.
Rinse the resin bed thoroughly.
Double regenerate the resin bed.
6.1.2
HYDROCHLORIC ACID (HCl) CLEANING
6.1.2.1 The HCl cleaning is used to remove iron, calcium, and magnesium from cation resin and
sometimes from anion resin. If anion resin is to be cleaned, it is first backwashed and
exhausted with a 10% brine solution to remove any residual alkalinity from the bed.
6.1.2.2 PROCEDURE
Backwash the bed for about 10 minutes at the normal rate.
Drain down to 5 cm above the resin bed level.
Inject one bed volume of 10% HCl with about 0.15-0.2% corrosion inhibitor (e.g.,
rodine 213 spl.) at the regenerant flow rate.
Agitate the bed to distribute the acid throughout the bed.
Allow to soak for 12 hours.
Rinse the resin bed thoroughly.
(HCl is very corrosive and the resistance of all surfaces exposed to acid should be
checked before applying this solvent, particularly if vessel internals are of stainless steel
construction. An alternate procedure, usually preferable when the service vessel
contains SS, involves transferring the resin into a separate corrosion resistant container.
This enables utilizing higher temperatures (600C) for cation resin, thereby effecting
better iron removal).
6.1.3
CAUSTIC TREATMENT OF MIXED BEDS

(For better separation)
6.1.3.1 When mixed bed resins fail to separate properly due to reasons other than severe fouling
by oil, organics, or biological growth, caustic treatment may be performed for better
separation. This procedure should be used sparingly, usually as a last resort to
replacement of resins.
Page - 13
Rev. No.: 0
Page - 14
Rev. No.: 0
6.1.3.2 PROCEDURE
Inject caustic regenerant (5%) at the normal regenerant flow rate for about 5-18
minutes and then immediately do the final fast rinse.
Repeat the procedure until the bed is fully exhausted. (The cation resin is converted to
most dense Na-form and anion resin to least dense OH-form).
Backwash to get a very clear cation/anion resin separation.
Triple regenerate the cation bed.
Regenerate anion resin with normal caustic dosage.
Page - 15
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7.0
MEASUREMENT OF BED DEPTH AND REMOVAL OF FINES
7.1
MEASUREMENT OF RESIN BED DEPTH
7.1.1
Open top manhole.
7.1.2
Slowly open wash inlet valves. The resin bed will be fluidized.
7.1.3
After 3-5 minutes carefully insert the measuring pipe into the vessel through the resin
until it reaches the bottom. The measuring pipe can be length of 25mm x 25mm wood
long enough to reach the bottom of the vessel. Alternatively a length of PVC, GI, or MS
pipe can be used. For rubber lined vessels, GI or MS pipes should not be used as they
may cause damage to the lining or to the collecting systems.
7.1.4
Hold the pipe vertical. Mark off distance to a convenient reference point such as the
manhole flange.
7.1.5
Repeat procedure to check depth at two other points. Remove the pipe.
7.1.6
Measure the distance marked off on the pipe (X).
7.1.7
Continue backwashing for 10 minutes. Close wash inlet valve and let the vessel drain
slowly at a flow rate not exceeding 4.5 m3/h/m2 of bed area.
7.1.8
When the water drains down to the resin bed level, close the rinse outlet valve.
7.1.9
Re-insert the measuring pipe through the manhole down to the bed surface and mark off
the depth to the same reference point. Repeat this at two other points.
7.1.10 Remove the pipe and measure this distance (Y).

7.1.11 Open the backwash inlet valve slowly and allow the vessel to fill up. When water comes
out from the wash outlet pipe, close the wash inlet valve. Close the manhole.
7.1.12 Calculate the depth of the resin bed (X-Y). Calculate the resin volume by multiplying the
resin depth with cross sectional area of the vessel. Compare the calculated volume with
the design value and top up if required. (The bed depth of SAC and SBA resins is
measured in the exhausted form).
Page - 16
Rev. No.: 0
7.2
REMOVAL OF RESIN FINES
7.2.1
Open the manhole.
7.2.2
Open the rinse outlet valve.
7.2.3
Drain the water till level is about 300 mm above the resin bed.
7.2.4
Insert an air hose (the air hose should be of sufficient length to reach the bottom of the
resin bed and should be weighed at end to facilitate its reaching the bottom of the resin
bed) into the resin bed taking care that it does not reach the bottom of the bed and disturb
the under bed if any.
7.2.5
Connect the hose to air supply (at 0.5 kg/cm2) and start the air.
7.2.6
Move the hose throughout the resin bed.
7.2.7
Continue the operation for 15 minutes.
7.2.8
Cut off air supply and remove the air hose.
7.2.9
Slowly open backwash inlet valve taking care that the effluent water does not carry good
resin beads during open backwash.
7.2.10 After the open backwashing is over, close the backwash inlet valve.
7.2.11 Open rinse outlet valve and drain the water to slightly below the resin bed level.
7.2.12 Scrap off 12 mm layer from the top of the resin bed and discard this.
7.2.13 Close the manhole cover.
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8.0
SAMPLING OF ION-EXCHANGE RESINS
8.1
SAMPLING
FROM
ION-EXCHANGE
UNRESTRICTED HEAD ROOM
8.1.1
APPARATUS
EQUIPMENT
HAVING
AN
8.1.1.1 Sampling devices as shown in Figures 1, 2, 3, and 4.

8.1.1.2 Containers- sealable, gas proof or Wide mouth, polythene/polypropylene, double capped,
1-liter capacity bottles.
8.1.1.3 Sample quartering material A 0.5x0.5 m sheet of glazed paper, oil cloth or flexible
plastic film.
8.1.2
PREPARATION FOR SAMPLING
8.1.2.1 For M.B. unit, backwash the bed after exhaustion, then regenerate, rinse and air mix.
8.1.2.2 For all other units, backwash the bed after exhaustion regenerate and rinse.
8.1.2.3 Open access opening on the top of the ion-exchange equipment. Drain water just to the
top of the bed.
8.1.2.4 Where the sample is to be completely reconditioned before analysis, steps 8.1.2.1 to
8.1.2.3 may be omitted.
8.1.3
SAMPLING PROCEDURE
8.1.3.1 Select a minimum of 6 points, evenly spaced, and if possible, on a circle approximately
2/3rd the diameter of the bed.
8.1.3.2 Thrust the sampling rod (Fig. 2) through the ion-exchange resin until the bed support can
be felt.
8.1.3.3 With a gentle up and down motion, slip the sampling tube (Fig. 1) over the top of the
sample rod and through the ion-exchange resin to seat on the upper conical stopper (Fig.
6).
8.1.3.4 Pull up on the rod to withdraw the sampling tube and empty the contents.
8.1.3.5 Repeat the steps 8.1.3.2 to 8.1.3.4 to obtain sufficient sample.
8.1.3.6 Alternatively a core sampler (Fig. 4) may be used to obtain the minimum six increments
at points located according to 8.1.3.1. The sampler must reach to within the bottom 50
mm of the ion exchange bed.
8.1.3.7 If the sample obtained is larger than required, reduce it by quartering technique.
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8.2
SAMPLING FROM ION-EXCHANGE HAVING RESTRICTED HEAD ROOM
8.2.1
APPARATUS
8.2.1.1
8.2.1.2
Sampling device (Fig. 3, 4, and 5)

Containers- sealable, gas proof or Wide mouth, polythene/polypropylene, double capped,
1-liter capacity bottles.
Sample quartering material A 0.5x0.5 m sheet of glazed paper, oil cloth or flexible
plastic film.
8.2.1.3
8.2.2
SAMPLING PROCEDURE
8.2.2.1
Insert the first section of the hollow sample probe guide about half its length into the ionexchange resin.
8.2.2.2 Screw the second section onto the first and insert about half its combined length.
8.2.2.3 Add as many incremental sections as needed to reach within 50 mm of the subfill.
8.2.2.4 Connect one end of the 6 mm soft copper water line to an external source of D.M. water.
8.2.2.5 Insert the free end of the water line into the exposed portion of the hollow sample probe
guide and slightly open the external water valve to give a small stream of water.
8.2.2.6 Insert the water line completely into the hollow sample probe guide. Continue the small
flow of water to just suspend the ion-exchange resin contained within the hollow sample
probe guide.
8.2.2.7 Connect the 9 mm polythene tubing to the eduction system suction connections and
attach a valved 9 mm water supply to the eduction system power connection.
8.2.2.8 Attach a convenient length of 12 mm outer diameter tubing to the discharge connection
of the eduction system. Insert the free end of the discharge tubing into a sample container.
8.2.2.9 Open the eduction system supply water and insert the eduction system suction tube into
the hollow, sample probe guide to withdraw the sample.
8.2.2.10 Continue inserting the suction tube further into the hollow, sample probe guide until all
the entrapped ion-exchange resin is withdrawn.
8.2.2.11 Alternatively a core sampler (Fig. 4) may be used to obtain the sample. The sampler must
reach to within the bottom 50 mm of the ion exchange bed.
8.2.2.12 If the sample quantity obtained is larger than required, reduce the sample using the
quartering technique.
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Rev. No.: 0
8.2.3
QUARTERING PROCEDURE
8.2.3.1
Spread the sample on the quartering material to form approximately 25 mm thick uniform
layer.
Remix the sample by lifting a corner of the sheet and drawing it across, low down, to the
opposite corner in a manner that the material is made to roll over and over and does not
merely slide along. Continue operation with each corner proceeding in a clockwise
direction. Repeat this operation 3 times.
Lift all four corners of the sheet towards the center and holding all four corners together,
raise the entire sheet into the air to form a pocket for the ion exchange resin.
Repeat step 8.2.3.1.
Divide the sample into quarters.
Discard alternate quarters.
Repeat steps 8.2.3.2 through 8.2.3.6 to get a minimum of 1 liter sample.
8.2.3.2
8.2.3.3
8.2.3.4
8.2.3.5
8.2.3.6
8.2.3.7
8.2.4
8.2.4.1
8.2.4.2
8.2.4.3
8.2.4.4
8.2.4.5
8.2.4.6
8.2.4.7
8.2.4.8
8.2.4.9
8.2.4.10
8.2.4.11
8.2.4.12
8.2.4.13
8.2.4.14
8.2.4.15
8.2.4.16
SAMPLE LABELLING
StationstagestreamSampling dateResin Brand NameResin Type : SAC/WAC/SBA(Type-I)/SBA(Type-II)/WBA/Mixed resins
Ionic Form : H+ / Na+ / NH4+, OH-/ ClVolume of Resin in the bedApproximate age of the resin in operationTotal number of regenerations carried out so farTotal number of each special treatments e.g. brine, hydrochloric acid, hypochlorite,
formaldehyde etc., if carried outTotal output (M3) Resin additions done (top up) DateQuantityIdle period (resin bed not in operation)Results of previous analysis, if carried out.
(Give details on a separate sheet)
Name of the analysis requiredReasons for sampling (Brief account for nature of problem faced, if any)Signature and the title of the sampler-
Page - 20
Rev. No.: 0
Figures 1 & 2
Figure-1
Figure-2
51 mm inside diameter plastic tube with 2.4 mm wall thickness

Ion-exchange sampling tube
Sampling Rod
Page - 21
Rev. No.: 0
Figures 3 & 4
TRIGGER CORD
5 FEET
EXTENSION HANDLES
5 FEET
TRIGGER HOOK
5 FEET
OR 8 FEET
CLEAR PLASTIC CORE

TUBE 1- INCH I.D.
STOPPER BALL
Figure 3
Sampling Apparatus in Place
Figure 4
Core Sampler
Page - 22
Rev. No.: 0
Figures 5 & 6
Figure 5
9.0
Hollow Sample Grab

Guide
Figure 6
Sampling Apparatus
REVIEW
The Head of Corporate Operation Services will be responsible for reviewing this
document on a 3-yearly basis or as necessary.
Page - 23
Rev. No.: 0
ANNEXURE-1
FILETR MEDIA HEIGHT/TOP UP
DATE:
STATION:
LOCATION:
FILTRATION SYSTEM:
PF/ GF/ ACF
FINES REMOVAL: Done/ Not done
S.NO. BED NO./ DESIGN
VESSEL
MEDIA
NO.
HEIGHT
(m)
MEASURED
MEDIA
HEIGHT (m)
TOP UP
QTY.
(M3)
REMARKS
SIGNATURE:
Page - 24
Rev. No.: 0
ANNEXURE-2
FILETR MEDIA REPLACEMENT
DATE:
STATION:
LOCATION:
FILTRATION SYSTEM :
S.NO.
BED NO./
VESSEL
NO.
PF/ GF/ ACF
MEDIA
PROVIDED
MEDIA QTY.
PROVIDED
(M3)
MEDIA
REPLACED
(M3)
REASONS FOR
MEDIA
REPLACEMENT
SIGNATURE:
REMARKS
Page - 25
Rev. No.: 0
ANNEXURE-3
FILETR MEDIA TREATMENT
DATE:
STATION:
LOCATION:
FILTRATION SYSTEM:
S.NO.
BED NO./
VESSEL
NO.
PF/ GF/ ACF
MEDIA
PROVIDED
TYPE
OF
TREATMENT
DONE
REASONS FOR
TREATMENT DONE
SIGNATURE:
REMARKS
Page - 26
Rev. No.: 0
ANNEXURE-4
RESIN HEIGHT/TOP UP
DATE:
STATION:
LOCATION: DM plant/ Softening plant/ CPU
TYPE OF RESIN:
WAC/ SAC/ WBA/ SBA
FINES REMOVAL: Done/ Not done
S.NO. VESSEL
NO.
DESIGN
RESIN
HEIGHT
(m)
MEASURED
RESIN
HEIGHT (m)
TOP UP
QTY.
(M3)
REMARKS
SIGNATURE:
Page - 27
Rev. No.: 0
ANNEXURE-5
RESIN REPLACEMENT
DATE:
STATION:
TYPE OF RESIN:
WAC/ SAC/ WBA/ SBA
S.NO.
VESSEL
NO.
RESIN
PROVIDED
RESIN QTY.
PROVIDED
(M3)
RESIN
REPLACED
(M3)
REASONS FOR
RESIN
REPLACEMENT
SIGNATURE:
REMARKS
Page - 28
Rev. No.: 0
ANNEXURE-6
RESIN TREATMENT
DATE:
STATION:
TYPE OF RESIN:
WAC/ SAC/ WBA/ SBA
S.NO.
VESSEL
NO.
RESIN
PROVIDED
TYPE
OF
TREATMENT
DONE
REASONS FOR
TREATMENT DONE
SIGNATURE:
REMARKS
Document for Distribution to:

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2. General Manager
3. General Manager
4. General Manager
5. General Manager
6. General Manager
7. General Manager
8. General Manager
9. General Manager
10. General Manager
11. General Manager
12. General Manager
13. General Manager
14. General Manager
15. General Manager
16. General Manager
17. General Manager
18. General Manager
19. General Manager
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UNCONTROLLED
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Tanda
Talcher Thermal
Auraiya
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Anta
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Head of O&M
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40. Farakka
41. Vindhyachal
42. Rihand
43. Kahalgaon
44. Dadri(Coal)
45. Unchahar
46. Talcher Kaniha
47.Talcher Thermal
48. Badarpur
49. Simhadri
50. Auraiya
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52. Kawas
55. Kayamkulam
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53. Jhanor Gandhar 54. Dadri (Gas)

57. Tanda
Head of Chemistry
58. Singrauli
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61. Farakka
62. Vindhyachal
63. Rihand
64. Kahalgaon
65. Dadri(Coal)
66. Unchahar
67. Talcher Kaniha
68.Talcher Thermal
69. Badarpur
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74. Jhanor Gandhar 75. Dadri (Gas)

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OPERATION INFORMATION NOTE

Manual on Quality Checks &

CORPORATE OPERATION SERVICES

National Thermal Power Corporation Ltd.

NATIONAL THERMAL POWER CORPORATION LTD.

Date : March, 2005

Manual on Quality Checks &

Quality checks for filter media, activated Carbon, &

Maintenance & Treatment of filter media and ACF

Fouling & degradation of ion exchange resins and

Treatment of ion exchange resins

Measurement of bed depth and removal of fines

Sampling of ion exchange resins

Formats for reporting various activities

National Thermal Power Corporation Ltd.

QUALITY CHECKS FOR FILTER MEDIA, ACTIVATED CARBON, & ION

PRESSURE FILTER AND GRAVITY FILTER

THE FILTERS SHOULD BE CHECKED FOR THE FOLLOWING

3.1.2.3 Bed capacity reduces to 60% w.r.t original capacity.

ACTIVATED CARBON FILTER

THE FILTERS SHOULD BE CHECKED FOR THE FOLLOWING:

National Thermal Power Corporation Ltd.

Particle size distribution.

3.2.2.3 Bed capacity reduces to 60% w.r.t original capacity.

ION EXCHANGE RESINS (DM PLANT, SOFTENER, CPU)

THE ION EXCHANGE RESINS BEDS SHOULD BE CHECKED FOR THE

3.3.1.1 Ion exchange vessels internal lining integrity.

National Thermal Power Corporation Ltd.

MAINTENANCE & TREATMENT OF FILTER MEDIA AND ACF

CRACKING OF SAND BED

National Thermal Power Corporation Ltd.

ACTIVATED CARBON FILTERS

STEAM CLEANING PROCEDURE

For steam cleaning separate arrangement is to be made as filters generally have

National Thermal Power Corporation Ltd.

HYDROCHLORIC ACID AND CAUSTIC CLEANING

Biological fouling can be reduced by cleaning with acidic or alkaline solutions.

Cleaning with a 5% caustic solution requires 10 to 15 hours due to excessive time

Note: Use formats in Annexures for recording the activities performed.

National Thermal Power Corporation Ltd.

FOULING & DEGRADATION OF ION EXCHANGE RESINS AND

DETECTION OF FOULING AND DEGRADATION OF ION EXCHANGE

Coating on beads from foulants or improper

Higher than expected

Smaller sizes than

Mixed bed resin

Ash content and

Higher than expected.

Poorer than expected.

Fouling of resin by oil, solvents etc., or

ESTIMATION OF ORGANIC FOULLING OF ANION EXCHANGE RESINS

Degree of organic fouling

National Thermal Power Corporation Ltd.

TREATMENT OF ION EXCHANGE RESINS

CHEMICAL CLEANING OF FOULED RESINS

Alkaline brine (or hypochlorite)

Caustic or Alkaline brine

growth Alkaline brine or caustic (or hypochlorite)

ALKALINE BRINE CLEANING

HYDROCHLORIC ACID (HCl) CLEANING

CAUSTIC TREATMENT OF MIXED BEDS

National Thermal Power Corporation Ltd.

National Thermal Power Corporation Ltd.