Guidelines for the commissioning

of the

ION-IX plant

CONTENTS
1.0

GENERAL

1.1

Safety precautions

1.2

First aid

1.3

Handling of chemicals

2.0

MECHANICAL

3.0

FLUSH

4.0

INSTRUMENTATION

5.0

PUMPS

6.0

RUNNING THROUGH THE ION-IX VALVE

7.0

AUTOMATION AND ALARMS

8.0

RUN ON WATER

9.0

DISTRIBUTOR ASSEMBLY AND RESIN FILL

10.0

FIRST REGENERATION

11.0

FIRST PRODUCTION

12.0

ATTENTION

13.0

CONTACT DETAILS

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Commissioning guidelines ION-IX Rev1

1.0

GENERAL
This document can be used as a lead for the commissioning and start-up of the new
ION-IX plant.
In this document a summary of the major commissioning steps is given.
It must be clear that this document is a lead and should therefore be interpreted as
such.

1.1

Safety precautions
Read the Operating and Maintenance Instructions manual prior to performing any
work on the ION-IX system. Strict compliance with the instructions in the Operating
and Maintenance Instructions manual is required.
Failure to observe these instructions can result in permanent damage to the unit,
significant property damage, or personal injury or death.
All people involved with the assembly or other works to the ION-IX system must
comply with all current environmental, health and safety regulations in addition to any
other site specific regulations. Works must only be carried out by specially trained
personnel and, if necessary, under supervision of a person qualified for this work.
Warnings are posted throughout the manual. These warnings are designated by an
exclamation mark inside an equilateral triangle.

If you do not understand the contents of this Mechanical Instructions manual, please
consult PuriTech for further information !

Protective or safety devices must not be removed, modified or readjusted.

During operation of the multi-port valve, none of the protective or safety devices must
be removed, modified or readjusted temporarily or permanently
Use only proper tools for maintenance and repair works
Use original spare parts only
All maintenance and repair works must be carried out whilst the valve is stationary and
disconnected from the power supply.
Ensure that the ION-IX valve can not be switched on by mistake. Use proper lock-out
tag-out procedure.

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Commissioning guidelines ION-IX Rev1

Prior to disconnecting a part under pressure, disconnect the ION-IX system from all
pressure sources and depressurise.
Do not use inflammable solvents or solvents, which could corrode the ION-IX valve
material, for cleaning.
Ensure that no tools, loose parts or similar are left in the system.
No mechanical damage may occur, to prevent the multi-port valve from leaking.

Consult the correct Material Safety Data Sheets of the different

process media before opening any process connection.
When disconnecting any process nozzles, use the correct personal safety equipment
1.2

First aid
If by any reason, a person gets injured or is in a need for help, follow these
instructions as a minimum.

1.3

Make sure the area is clear and safe to any other person or to yourself before taking
any action.
Remove the injured person immediately from the area if chemicals are cause of injury.
Call help services asap.
Splashes of chemicals in the eyes must be blown out with the mouth. Then rinse eyes
with plenty of water.
Do not wipe with cloth !
If the victim is not breathing, perform a mouth-to-mouth resuscitation or use a
respirator until qualified medical personnel arrive on the scene.
Inform medical staff of all facts regarding the incident and inform him by what the
incident is caused.
Verify on the Material Safety Data Sheet what actions to be taken.
Never leave the victim unattended !
Handling of chemicals

Wear eye protection and protective gloves wear all appropriate PPE
Avoid contact of chemicals with your skin
Do NOT inhale chemical vapours.
To avoid higher concentrations of chemical vapours, all work rooms must be well
ventilated.
Leave the room immediately if there is any suspicion of contamination and only reenter the work area after the room has been sufficiently ventilated.

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Commissioning guidelines ION-IX Rev1

2.0

MECHANICAL
All equipment is installed
All bolts are present and tightened
All supporting is installed and fixed
All valves can open and close without any friction

3.0

FLUSH
During mechanical erection, dust, sand, piping material and even bolts or other
undesired items can be found in the system.
As this may cause severe damage to the equipment it is very important to remove
these undesired items from the system.
Therefore, before running pumps or sending flow through the ION-IX valve, all tanks
and pipes need to be flushed with water.
For the ion exchanger vessels, this should be done without the distributors mounted.
After the flushing, tanks and ion exchangers should be emptied and all undesired
material needs to be removed.

4.0

INSTRUMENTATION
If the system has been cleaned, all instruments can be checked and calibrated.
Ensure that each instrument loop is complete and working properly.
Calibration of the complete instrument loop needs to be checked.
As for the level transmitters of the tank, it is advised to calibrate when the tank is
empty and make necessary checks.
Fill up each tank with water for approximately 50%. This water can then be used for
running pumps and venting lines.
Check level on the transmitter and SCADA and compare with real level. Adjust if
necessary.
This step is important as to ensure that the tanks can be used at full capacity and
protection levels can be set correctly.
Ensure that flow transmitters and flow control loops work properly.
Ensure that all other instrument loops work properly.
Install the encoder on the ION-IX valve and check if working properly.

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Commissioning guidelines ION-IX Rev1

5.0

PUMPS
Check alignment and rotation sense with disassembly of motor-pump coupling.
Vent the suction line and pump to ensure no air can get into the pump.
Open slightly the pressure side valve and run the pump.
Each pump group has a leak flow line to prevent pumps from running dry. Through this
line the system can be vented and pump should reach its maximum designed
pressure. If not, investigation needs to be done.
Open manually the rest of this pipe line and vent the line completely ( the ION-IX valve
is still not finally connected !! ).
Check values on flow transmitters.

6.0

RUNNING THROUGH THE ION-IX VALVE

The IONEX valve can now be fully connected.
Start to run each line separately on manual low flow rate.
Check on leaks and investigate if necessary.
Check if flow regulation works properly.
Check all levels in tanks and refill if necessary.
Put each process step of the ION-IX valve at approximately 3 bar.
Check rotation on the drives.
Start alignment of the ION-IX valve ( this must be done under pressure to avoid any
damage on the equipment !! ).

7.0

AUTOMATION AND ALARMS

Check on all alarms and interlock loops.
Start to run the program on low flow rates, this to avoid to spill too much water.
Check every step in the field and through SCADA.
If need be, corrections should be implemented and retested.
Ensure to have at least done one full cycle of the valve. This to ensure all ion
exchangers and lines are free of air.

8.0

RUN ON WATER
Run the plant on water at designed flow rates and check on failures.
Correct if necessary.

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Commissioning guidelines ION-IX Rev1

9.0

DISTRIBUTOR ASSEMBLY AND RESIN FILL

Drain the ion exchanger vessels and open all manholes if there are any.
Check internal of each ion exchanger on dirt or other undesired items.
If need be investigate the cause of what has been detected.
Put the distribution system in place.
To ensure no stainless steel to stainless steel gripping, we advise to put some teflon
tape over the wire.
Check if all distributor arms show no damage or other that can cause any problem.
Start the filling of the resin.
Ensure that the right resin is in the right place and that the right volumes are being
used in each ion exchanger.

10.0 FIRST REGENERATION

From this moment it must be clear to all people attending to the plant that
chemicals will be present in the system !!!
Drain the water out of the chemicals tanks.
Prepare the eluant solution(s). Be aware of the possible exothermal reaction of
this !!
Run the plant and ensure preconditioning step, elution steps and rinse steps work
properly.
Keep adsorption at minimal flow rate and pressure.

11.0 FIRST PRODUCTION

When first regeneration has been done successfully, the plant can be started in full
automatic.
The first few hours, the product will not be as per specification.
Once the system is balanced, product will meet specifications.
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Commissioning guidelines ION-IX Rev1

12.0 ATTENTION

If any hazard, leak or abnormal situation is detected, the plant should be stopped and
investigation should be done.
.

13.0 CONTACT DETAILS

Head office:
PuriTech Ltd
110 Sundrive Road,
Dublin 12
Ireland
Workshop Technical assistance:
PuriTech Ltd
Industriezone Dikberd 14
Unit 10 A
B-2200 Herentals
Belgium
Phone :

+32-14-70.50.41

Fax :

+32-14.70.50.41

e-mail :

info@puritech.be

website :

http://www.puritech.be

AFTER SALES SUPPORT:

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phone +32-14-70.50.41

Commissioning guidelines ION-IX Rev1