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Dupont IntegraTec Ultrafiltration T-Rack Manifold II P Series Assembly Instructions Manual

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Water Solutions
DuPont™ IntegraTec™ P Series
Ultrafiltration T-Rack™ Manifold II
Assembly Instructions
Version 5
October 2022
NOTICE: The information provided in this literature is given in good faith for informational purposes only. DuPont assumes no
obligation or liability for the information presented herein. NO WARRANTIES ARE GIVEN; ALL IMPLIED WARRANTIES OF
MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE ARE EXPRESSLY EXCLUDED
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Summary of Contents for Dupont IntegraTec Ultrafiltration T-Rack Manifold II P Series

  • Page 1 October 2022 Powered by NOTICE: The information provided in this literature is given in good faith for informational purposes only. DuPont assumes no obligation or liability for the information presented herein. NO WARRANTIES ARE GIVEN; ALL IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE ARE EXPRESSLY EXCLUDED...

  • Page 2: Table Of Contents

    Index Table of Contents Legal Notice ................................. 4 Product ..........................................4 Change Policy ........................................4 About these Instructions .............................. 5 Objective of these Instructions ................................. 5 Target Groups ........................................6 2.2.1 Qualified Personnel ..................................6 2.2.2 Skilled Persons with a Supervisory Capacity........................6 2.2.3 Involvement of Other Persons ..............................
  • Page 3 Index Storage ..........................................31 5.5.1 Suitability of the Location ............................... 31 5.5.2 Stackability ....................................31 5.5.3 Checking the Available Space .............................. 31 Installation / Assembly .............................. 32 Warnings .......................................... 32 General Specifications ....................................34 6.2.1 Hazards......................................34 6.2.2 Intended Usage................................... 34 6.2.3 Unauthorized Usage .................................

  • Page 4: Legal Notice

    Legal Notice Legal Notice Product DuPont™ IntegraTec™ Series P Pressure-UF In-Out T-Rack™ Manifold, parts and components for installation, assembly and disassembly Duplication and archiving in any form whatsoever – including of excerpts – is only permitted with the written consent of the manufacturer.

  • Page 5: About These Instructions

    In the event of making a warranty claim, the operator agrees to automatically provide DuPont™ with a complete set of documentation. Please contact DuPont™ if you wish to deviate from any of the guidelines or specifications provided in this document and request written approval in advance.

  • Page 6: Target Groups

    About these Instructions Target Groups 2.2.1 Qualified Personnel These instructions are intended for skilled persons with the following qualifications: • Technical education The skilled person must have technical education as a mechanic or mechatronics technician, for example. • Several years of experience with the installation of industrial systems The skilled person must also have several years of experience with the installation of industrial systems.

  • Page 7: Symbols

    About these Instructions 2.3.2 Symbols The following symbols are used in this manual: SYMBOL DESCRIPTION (EXAMPLES) IMPORTANT NOTE! Failure to follow the instructions in this note may lead to problems with the product. INFORMATION! Following this information will make it easier to assemble the T-Rack™...

  • Page 8: Safety

    The installed T-Rack™ Manifold is only intended for the commercial ultrafiltration of water. The intended installation and disassembly includes adherence to all specifications in these instructions. Any other method of installation or disassembly is considered to be unintended use. DuPont™ cannot be held liable for damage that results from unintended use.

  • Page 9: Residual Risks

    Safety 3.2.1 Residual Risks Despite the inherently safe design the following residual risks remain: • Danger of crushing from falling raised loads • Danger of crushing by industrial trucks and other equipment at the construction site • Danger of injury from faulty and incomplete assembly •...

  • Page 10: Standards And Laws

    Safety Standards and Laws • The T-Rack™ Manifold of DuPont™ is subject to the EU Pressure Equipment Directive 2014/68/EU, Article 4, Sector 3. • The locally applicable normative and/or statutory requirements for the installation and disassembly of the T- Rack™ Manifold must be complied with.

  • Page 11: General Information On Safety And Warning Instructions

    Safety General Information on Safety and Warning Instructions 3.6.1 Categories and Structure Depending on the severity of the impending or potential danger, the following types of safety and warning instructions are differentiated: DANGER DANGER TO LIFE! Personal injury due to an imminently hazardous situation. If this situation is not avoided, it will lead to serious injury or death.

  • Page 12: Warning Symbols

    Safety 3.6.2 Warning Symbols The following warning symbols are used in this manual: WARNING DESCRIPTION SYMBOL GENERAL DANGER SIGN If the necessary safety instructions are not followed, this may lead to death, serious injury and serious property damage. SUSPENDED LOADS If the necessary safety instructions are not followed, this may lead to death, serious injury and property damage due to falling loads.

  • Page 13: Signs Giving Instructions

    Safety 3.6.3 Signs Giving Instructions The following signs giving instructions are used in this manual for the required personal protective equipment (PPE): DESCRIPTION SIGNS GIVING INSTRUCTIONS WORKING WITH A HELMET Failure to wear a helmet may result in head injuries. •...
  • Page 14 Safety DANGER DANGER TO LIFE! Danger of crushing by industrial trucks and other equipment at the construction site. • Keep a sufficient distance when transporting and lifting loads! • Wear a safety helmet! • Wear safety shoes! WARNING CONSIDERABLE DANGER OF INJURY! Danger of injury from faulty and incomplete assembly.
  • Page 15 Safety WARNING CONSIDERABLE DANGER OF INJURY! Danger of crushing and shearing from work in the danger zone. • Note the specified number of persons required! • Wear safety gloves! • Wear safety shoes! WARNING CONSIDERABLE DANGER OF INJURY! Cutting and impact injuries from sharp corners and edges.

  • Page 16: Position Of Warnings

    DANGER OF INJURY! Danger of injury during operation due to the installation and use of damaged parts. • Only use undamaged parts or parts approved by DuPont™! 3.6.5 Position of Warnings • General warnings on activities are found at the beginning of each main section.

  • Page 17: Device Description

    Device Description Device Description The T-Rack™ Manifold II forms the interface between the T-Rack™ (see corresponding DuPont™ product documentation) and the plant's connecting pipework (main pipelines). The hydro dynamically optimized design of the T-Rack™ Manifold is tailored to the specific requirements of the T-Rack™.

  • Page 18: T-Rack™ Manifold Ii Grp - Single-Sided Connection

    Device Description T-Rack™ Manifold II GRP – Single-sided connection 4.1.1 Components The T-Rack™ Manifold consists of the following components: Figure 1: T-Rack™ Manifold II GRP - Single-sided connection Page 18 of 67 Form No. 45-D02232-en, Rev 5 October 2022...

  • Page 19: Parts List

    Device Description 4.1.2 Parts List Part Quantity Single part Feed header (bottom) Feed header (top) Filtrate header T-header T-piece - CIP (feed inlet) and Drain / Instrumentation T-piece - CIP (feed outlet) and Vent / Instrumentation T-piece - CIP (filtrate outlet) and Vent / Instrumentation Interconnecting pipe feed bottom (short+long) Interconnecting pipe feed top (short+long) Interconnecting pipe filtrate (short+long)

  • Page 20: Functional Description

    Device Description 4.1.3 Functional Description Part Description Feed header (bottom) Central header with one inlet port, one outlet port Backwash, 8 ports 6" to connect the T-Rack™ and one port T-piece – CIP Feed header (top) Central header with one outlet port, 8 ports 6" to connect the T-Rack™ and one port T-piece –...

  • Page 21: T-Rack™ Manifold Ii Grp - Double-Sided Connection

    Device Description T-Rack™ Manifold II GRP – Double-sided connection 4.2.1 Components The T-Rack™ Manifold consists of the following components: Figure 2: T-Rack™ Manifold II GRP - Double-sided connection Page 21 of 67 Form No. 45-D02232-en, Rev 5 October 2022...

  • Page 22: Parts List

    Device Description 4.2.2 Parts List Part Quantity Single part Feed header (bottom) Feed header (top) Filtrate header T-header T-piece - CIP (feed inlet) and Drain / Instrumentation T-piece - CIP (feed outlet) and Vent / Instrumentation T-piece - CIP (filtrate outlet) and Vent / Instrumentation Interconnecting pipe feed bottom (short+long) Interconnecting pipe feed top (short+long) Interconnecting pipe filtrate (short+long)

  • Page 23: Functional Description

    Device Description 4.2.3 Functional Description Part Description Feed header (bottom) Central header with one inlet port, one outlet port Backwash, 8 ports 6" to connect the T-Rack™ and one port T-piece – CIP Feed header (top) Central header with one outlet port, 8 ports 6" to connect the T-Rack™ and one port T-piece –...

  • Page 24: T-Rack™ Manifold Ii Pe - U-Shape

    Device Description T-Rack™ Manifold II PE – U-Shape 4.3.1 Components The T-Rack™ Manifold II PE consists of the following components: Figure 3: T-Rack™ Manifold II PE - U shape Page 24 of 67 Form No. 45-D02232-en, Rev 5 October 2022...

  • Page 25: Parts List

    Device Description 4.3.2 Parts List Part Quantity Single part 1 each Feed header (bottom) - Center, left, right 1 each Feed header (top) - Center, left, right 1 each Filtrate header - Center, left, right T-header T-piece - CIP (feed inlet) and Drain / Instrumentation T-piece - CIP (feed outlet) and Vent / Instrumentation T-piece - CIP (filtrate outlet) and Vent / Instrumentation Interconnecting pipe feed bottom (long)

  • Page 26: Functional Description

    Device Description 4.3.3 Functional Description Part Description Feed header (bottom) Central header with one inlet port, one outlet port Backwash, 8 ports 6" to connect the T-Rack™ and one port T-piece – CIP Feed header (top) Central header with one outlet port, 8 ports 6" to connect the T-Rack™ and one port T-piece –...

  • Page 27: Technical Data

    • DuPont™ IntegraTec™ T-Rack™ Manifold II (PE) Product Data Sheet (Form No. 45-D02564-en) • DuPont™ IntegraTec™ Valves Kit for T-Rack™ Manifold II (GRP and PE) Product Data Sheet (Form No. 45-D02271-en) Page 27 of 67 Form No. 45-D02232-en, Rev 5...

  • Page 28: Loading, Transport And Storage

    • Components that are irreparably destroyed due to improper loading, transport or storage shall not be covered by DuPont™ IntegraTec™ warranty provisions. Therefore, it is important to always follow the loading, transport and storage instructions provided in these Assembly Instructions.
  • Page 29 Loading, Transport and Storage DANGER DANGER TO LIFE! Danger of crushing by industrial trucks and other equipment at the construction site. • Keep a sufficient distance when transporting and lifting loads! • Wear a safety helmet! • Wear safety shoes! WARNING CONSIDERABLE DANGER OF INJURY! Danger of falling when using ladders, scaffolding and...

  • Page 30: Loading

    Loading, Transport and Storage WARNING CONSIDERABLE DANGER OF INJURY! Danger of tripping and impact from pallets, packages and assembled parts at the construction site. • Wear a safety helmet! • Wear safety shoes! CAUTION DANGER OF INJURY! Danger of injury due to physical strain. •...

  • Page 31: Transport

    Loading, Transport and Storage Transport 5.4.1 Transport Conditions • During transport, adhere to a temperature range of -20°C to 40°C. • Ensure that the equipment is transported and stored in an enclosed area to keep the components from getting wet and to protect them against excessive heat and direct sunlight. 5.4.2 Checking the Freight Check on IPPC Pallets...

  • Page 32: Installation / Assembly

    Installation / Assembly Installation / Assembly Warnings DANGER DANGER TO LIFE! Danger of crushing from falling raised loads. • Never stand under raised loads! • Keep a sufficient distance when transporting and lifting loads! • Wear a safety helmet! • Wear safety shoes! WARNING CONSIDERABLE DANGER OF INJURY!
  • Page 33 Installation / Assembly WARNING CONSIDERABLE DANGER OF INJURY! Cutting and impact injuries from sharp corners and edges. • Wear safety gloves! • Wear safety shoes! WARNING CONSIDERABLE DANGER OF INJURY! Danger of tripping and impact from pallets, packages and assembled parts at the construction site. •...

  • Page 34: General Specifications

    Intended Usage Workplace safety can only be guaranteed if the T-Rack™ Manifold is used as intended. This includes observing all DuPont™ relevant product information as well as the manuals provided by suppliers. It also includes performing maintenance and service work.

  • Page 35: Staff Training

    6.2.9 Structural Changes of the Plant Structural changes of the plant and the equipment require written authorization from DuPont™. All warranty and liability claims are rendered void if these instructions are violated. The owner is responsible for workplace safety and the overall functioning of the plant if wear, tear and spare parts are replaced with non-original parts.

  • Page 36: Lubricating Parts

    Ensure that no damaged parts are installed. If damaged parts are found, immediately contact DuPont™ and return the parts. Attention needs to be paid to not leave any assembly residues behind. Assembly residues need to be removed if present.

  • Page 37: Required Tools

    Installation / Assembly 6.2.12 Required Tools NOTE CAUTION, PROPERTY DAMAGE! If the tightening torques specified in this instruction are exceeded, the system parts may become damaged, and leaks may occur during operation. • Always adhere to the specified tightening torques! For the entire setup of T-Rack™...

  • Page 38: Checking The Delivery

    All parts without damage • Damaged parts with written approval from DuPont™ with a specific reference to the damaged module or part DuPont™ decides on the procedure (approval or block) for all damaged parts that have not been approved. CAUTION...

  • Page 39: Checking The Delivery For Completeness

    Check the completeness of the delivery against the packing list. All packages on the packing list must be present. Promptly inform your contact at DuPont™ if the number of pieces differs between the packing list and the existing packages. 6.4.4...

  • Page 40: Assembly Of The T-Rack™ Manifold Ii

    Frame alignment must be in accordance with customer reference and overall structure (including T-Rack™ and modules). NOTE Use copper paste (or comparable material) for stainless steel screws. The required bolts to connect the valves are not within DuPont™s scope of supply! 6.5.1 T-Rack™...

  • Page 41: T-Rack™ Manifold Ii Grp - Double-Sided Connection

    Installation / Assembly 6.5.2 T-Rack™ Manifold II GRP – Double-sided connection Step Activity Figure Assembly frame Rectangular Manifold Connect the rectangular Manifold frame top (delivered frame top completely welded) to the 4 Manifold feet by using the enclosed screws. The base plates are already welded at the feet. Align the frame in accordance with the general arrangement drawings.
  • Page 42 Installation / Assembly Step Activity Figure Positioning and alignment of base plates Position the base plates of the Feed header with the project drawings. Base plates of the feed header Anchoring and height adjustment of the frame The frame and base plates shall be bolted to the floor using anchoring bolts (M16).
  • Page 43 Installation / Assembly Step Activity Figure Assembly Feed header bottom Position the Feed header bottom (A) and screw it to flange supports Ensure horizontal and vertical alignments by using a calibrated spirit level. Page 43 of 67 Form No. 45-D02232-en, Rev 5 October 2022...
  • Page 44 Installation / Assembly Step Activity Figure Assembly Feed header top Position the Feed header top (B). Ensure that the header cannot fall off! Screw the Feed header top (B) to the flange support with 2 screws each. This flange connection is only temporary until either the valves or the counter flange are installed.
  • Page 45 Installation / Assembly Step Activity Figure Assembly Filtrate header Position the Filtrate header (C). Mount it with 2 screws each to the flange support. The flange of the Filtrate header (C) and the flange of the Feed header top (B) have to be perfectly aligned. Fix the Manifold foot to the frame with 2 additional screws.
  • Page 46 Installation / Assembly Step Activity Figure Assembly T-pieces - CIP feed / filtrate and Drain / Instrumentation Position the T-piece - CIP (feed inlet) and Drain / Instrumentation (E) opposite the connection flange on the Feed header bottom (A) and tighten it to the flange by use of rubber gaskets, bolts, nuts and washers to the flange.
  • Page 47 Installation / Assembly Step Activity Figure Inspection of the dimensions Measure the horizontal offset between Feed header top (B) and Filtrate header (C). Compare the measurement with the dimensions given in the technical drawings. Correct the position if necessary to prevent the connection to the T-Rack™...
  • Page 48 Installation / Assembly Step Activity Figure Move to the Filtrate header (C) and repeat Steps 13. c) to 13. i) to install the interconnecting pipe filtrate (J) Move to the Feed header bottom (A) and repeat Steps 13. c) to 13.

  • Page 49: T-Rack™ Manifold Ii Pe - U-Shape Connection

    Installation / Assembly 6.5.3 T-Rack™ Manifold II PE – U-Shape connection Step Activity Figure Assembly frame Rectangular Manifold frame top Connect the two rectangular Manifold frames top (delivered completely welded) to the 4 Manifold feet by using the supplied screws. Manifold feet (4 / frame) Positioning and alignment frame...
  • Page 50 Installation / Assembly Step Activity Figure Anchoring and height adjustment of the frame Bolt the frame and bottom supports to the floor using anchoring bolts (M16). Nuts and washers must be placed under the steel plate to adjust the height of the frame. The gap between floor and steel plate should be filled with e.g.
  • Page 51 Installation / Assembly Step Activity Figure Assembly Feed header bottom - center Position the Feed header bottom - center (A Adjust the height as described in Step 3. Insert rubber gaskets between flanges and loosely connect the flanges together. Ensure horizontal and vertical alignments of the Manifolds by using a calibrated spirit level.
  • Page 52 Installation / Assembly Step Activity Figure Assembly of the Feed header top - center Position the Feed header top – center (B Insert rubber gaskets between flanges and loosely connect the flanges together. Ensure horizontal and vertical alignments of the Manifolds by using a calibrated spirit level.
  • Page 53 Installation / Assembly Step Activity Figure Assembly Filtrate header - center Position the Filtrate header top – center (C ) by using only the lower flanges bolts on the left and right. The gap between Filtrate header left and center is for the valve to be installed in the next step.
  • Page 54 Installation / Assembly Step Activity Figure Backwash outlet valves Position and attach the Backwash outlet top valve (5) by using centering bolts. Position and attach the Backwash outlet bottom valve (4) by using centering bolts. No rubber gaskets are needed for wafer style valves. Assembly T-header Attach and align the T-header (D) with the Backwash outlet valves (4) and (5).
  • Page 55 Installation / Assembly Step Activity Figure Inspection of the dimensions Measure the distance between Feed Header Top (B) and Filtrate Header (C). Compare the measurement with the dimensions given in the technical drawings. Correct the position if necessary to prevent the connection to the T-Rack™...
  • Page 56 Installation / Assembly Step Activity Figure Installation of the interconnecting pipes Remove the gaskets of the flexible composite couplings 6”. Lubricate the gaskets with glycerin on the inside and outside. Install one interconnecting pipe feed top (I) and connect it to the first connection on the feed header top (B) by using a lubricated gasket Place a flexible coupling 6”...

  • Page 57: T-Rack™ Assembly

    Once the T-Rack™ Manifold has been installed, assembly of the T-Rack™ and connection to the T-Rack™ Manifold can begin. To install the T-Rack™ please follow: • DuPont™ IntegraTec™ PES-UF In-Out P Series T-Rack™ Assembly Manual (Form No. 45-D02230-en) T-Rack™ Manifold II PE – U-Shape connection T-Rack™ Manifold II GRP- Double-sided connection Figure 4: Examples of T-Rack™...

  • Page 58: Service And Maintenance

    Service and Maintenance Service and Maintenance Warnings DANGER DANGER TO LIFE! Danger of crushing from falling raised loads. • Never stand under raised loads! • Keep a sufficient distance when transporting and lifting loads! • Wear a safety helmet! • Wear safety shoes! WARNING CONSIDERABLE DANGER OF INJURY!
  • Page 59 Service and Maintenance WARNING CONSIDERABLE DANGER OF INJURY! Cutting and impact injuries from sharp corners and edges. • Wear safety gloves! • Wear safety shoes! WARNING CONSIDERABLE DANGER OF INJURY! Danger of tripping and impact from pallets, packages and assembled parts at the construction site. •...

  • Page 60: Checks During Operation

    When doing so, note the warnings and instructions provided in → section 6 Installation / Assembly. 7.2.2 Exchanging Parts When exchanging parts, only original parts from DuPont™ are permitted to be used. Page 60 of 67 Form No. 45-D02232-en, Rev 5 October 2022...

  • Page 61: Return Of Manifold Components

    Manifold. This is also valid for permitted media, chemicals, and temperature and pressure ranges. Returns shall only be accepted if this has been agreed in advance with DuPont™ and authorized in writing. Returns that have been previously agreed and approved by DuPont™ are subject to the following mandatory requirements: •...

  • Page 62: Disassembly And Disposal

    Disassembly and Disposal Disassembly and Disposal Warnings DANGER DANGER TO LIFE! Danger of crushing from falling raised loads. • Never stand under raised loads! • Keep a sufficient distance when transporting and lifting loads! • Wear a safety helmet! • Wear safety shoes! WARNING CONSIDERABLE DANGER OF INJURY!
  • Page 63 Disassembly and Disposal WARNING CONSIDERABLE DANGER OF INJURY! Cutting and impact injuries from sharp corners and edges. • Wear safety gloves! • Wear safety shoes! WARNING CONSIDERABLE DANGER OF INJURY! Danger of tripping and impact from pallets, packages and assembled parts at the construction site. •...

  • Page 64: Disassembly

    Disassembly and Disposal Disassembly Disassembly work may only be performed by trained and qualified personnel or by a suitable specialist company. Adequate clear space for movement must be provided to perform the work. The danger area should, if necessary, be marked for third parties and/or cordoned off.

  • Page 65: Customer Service

    Article number NOTE A detailed list of the individual components can be found in the spare parts lists. The spare parts lists will be made available to you by DuPont™ on request. Page 65 of 67 Form No. 45-D02232-en, Rev 5...

  • Page 66: 10 Technical Documentation

    (Form No. 45-D02230-en) • DuPont™ IntegraTec™ PES-UF In-Out T-Rack™ Product Data Sheet (Form No. 45-D02241-en) As a components supplier, DuPont™ refers to the system supplier for further documents (for example System operating instructions). Page 66 of 67 Form No. 45-D02232-en, Rev 5...
  • Page 67 ARE EXPRESSLY EXCLUDED. No freedom from infringement of any patent or trademark owned by DuPont or others is to be © 2022 DuPont. DuPont™, the DuPont Oval Logo, and all trademarks and service marks denoted with ™, ℠ or ® are owned inferred.

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