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GE WATER & PROCESS TECHNOLOGIES
E-CELL STACK™
MK-2 SERIES
OWNER'S MANUAL
© 2006, General Electric
All rights reserved. No part of this publication may be reproduced, stored in a retrievable
system, or transmitted, in any form or by any means, electronic, mechanical, photocopying,
recording or otherwise, without the prior written permission of GE.
For additional E-Cell Stack™ information, go to the GEWPT E-Cell web page:
http://www.ecell.com
rev.1.1
Page 1-1
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Related Manuals for GE E-CELL STACK MK-2 Series
Summary of Contents for GE E-CELL STACK MK-2 Series
- Page 1 All rights reserved. No part of this publication may be reproduced, stored in a retrievable system, or transmitted, in any form or by any means, electronic, mechanical, photocopying, recording or otherwise, without the prior written permission of GE. For additional E-Cell Stack™ information, go to the GEWPT E-Cell web page: http://www.ecell.com...
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Page 2: Table Of Contents
TABLE OF CONTENTS E-CELL STACK™ GLOSSARY ....................1-2 PERSONNEL SAFETY PRECAUTIONS ................. 2-3 SPECIFICATIONS ......................... 3-5 FEED WATER SPECIFICATIONS ..................3-5 PRODUCT WATER SPECIFICATIONS ................3-6 SALT SPECIFICATIONS ....................3-6 E-CELL STACK™ OPERATING PARAMETERS..............3-6 E-CELL STACK™ TECHNICAL DATA SHEET ..............3-7 PERFORMANCE DATA .................... - Page 3 PREVENTATIVE MAINTENANCE................. 11-22 11.1 GENERAL........................11-22 11.2 E-CELL STACK CLEANING AND SANITIZING ............11-22 ™ 11.2.1 Overview......................11-22 11.2.2 Safety ....................... 11-24 11.2.3 Cleaning Chemical Specifications..............11-24 11.3 CLEANING SETUP AND INSTRUCTIONS ..............11-24 11.4 CLEANING PROCEDURES ..................11-27 Cleaning Procedure 1: Hydrochloric Acid Cleaning of Concentrate and Electrode Chambers ..............................
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Page 4: E-Cell Stack™ Glossary
™ E-Cell System , which will be sent directly to drain after ™ exiting the System. GEWPT GE Water and Process Technology. PRODUCT The deionized water which is produced by the E-Cell System™. RECTIFIER DC power supply. rev.1.1... -
Page 5: Personnel Safety Precautions
PERSONNEL SAFETY PRECAUTIONS The following Pictograms can be found on the E-Cell Stack™ and contained in this Manual: Pictogram Function Description WARNING! The E-Cell Stack™ should not be used at any time by untrained personnel. Do not attempt to operate the E-Cell Stack™ unless you understand the contents of this manual and have received training . - Page 6 POST THIS WARNING PAGE ON YOUR E-CELL SYSTEM Warning To Prevent Stack Damage WARRANTY MAY BE VOIDED IF THE FOLLOWING PRECAUTIONS ARE NOT FOLLOWED! Blockage or interruption of flow will damage stacks . If stacks are powered electrically without the flow of water through any channels, they will be irreversibly damaged in 1-3 minutes. Systems with an open system between the RO and E-Cell (ex.
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Page 7: Specifications
SPECIFICATIONS FEED WATER SPECIFICATIONS Constituent Units Feed ppm as CaCO * As calculated by E-Calc 5 to 9 Hardness ppm CaCO < 0.5 ** Silica (reactive) < 0.5 @ Minimum to Nominal product flow Silica (reactive) < 0.383 @ Maximum product flow <... -
Page 8: Product Water Specifications
PRODUCT WATER SPECIFICATIONS The E-Cell Stack will produce 16 MOhm.cm water (MK-2E, MK-2Mini, MK-2MiniHT) or 10 ™ MOhm.cm (MK-2Pharm, MK-2PharmHT), provided the feed water meets the Feed Water Specifications and the system is operated according to the Operating Instructions. SALT SPECIFICATIONS Proper salt selection for brine injection is critical in avoiding long term problems with scaling and fouling. -
Page 9: E-Cell Stack™ Technical Data Sheet
E-CELL STACK™ TECHNICAL DATA SHEET Design Pressure of E-Cell Stack ................100 psig (6.8 Bar) ™ Membrane Manufacturers ............Asahi Glass Corporation (AGC) Ion Exchange Manufacturers................Mitsubishi Chemical Model Designations ....MK-2E, MK-2Pharm, MK-2PharmHT, MK-2Mini, MK-2MiniHT Anode Material........................IrO /TiO on Ti Cathode Material ........................Stainless Steel Operating Weight ......................... -
Page 10: E-Cell™ Ce, Csa And Nrtl/C Compliance
E-CELL™ CE, CSA and NRTL/C COMPLIANCE The E-Cell Stack™ meets the principle elements of the safety objectives for the low voltage directive, EC Directive 73/23/EEC, having applied the following standard: BS EN 60204-1. The E-Cell Stack™ meets the principal elements of the safety objectives for the electro- magnetic compatibility directive, EC Directive 89/336/EEC (as amended by 92/31/EEC and 93/68/EEC). -
Page 11: E-Cell Stack™ Maximum Power Requirements
E-CELL STACK™ MAXIMUM POWER REQUIREMENTS INPUT INPUT VOLTAGE CURRENT POWER 100-600V 0.5-4.5A 2.7 kW OPERATING CURRENT In order for the E-Cell Stack™ to produce high quality water, the current flow must be sufficient for the ionic load in the feed water. In general, more current is required as the ionic load increases. -
Page 12: Receiving & Installation
RECEIVING & INSTALLATION RECEIVING Inspect each E-Cell Stack™ for shipping damage and then replace the packaging material. The Stacks should remain in the packaging material until they are to be installed. Any shipping damage must be reported to the shipper and E-Cell within 5 days to validate claim. LIFTING There are lifting lugs at the top of the E-Cell Stack™... -
Page 13: Drains & Venting
DRAINS & VENTING Drains should be designed to carry away 20 gpm (4.54 m /hr) Product flow, 0.40 gpm (90 L/hr) Electrode Outlet flow, and 1.97 gpm (0.45 m /hr) Concentrate Bleed flow for each MK-2E, MK- 2Pharm or MK-2PharmHT Stack; and 6.7 gpm (1.52 m /h) Product flow, 0.40 gpm (90 L/hr) Electrode Outlet flow, and 0.91 gpm (0.21 m /hr) Concentrate Bleed flow for each MK-2Mini... -
Page 14: Start Up
START UP GENERAL OVERVIEW The basic steps involved in the system start up are: 1. Fill the system with Reverse Osmosis quality water, or better 2. Set dilute flow 3. Start the concentrate pump and establish concentrate flow 4. Set concentrate bleed flow 5. -
Page 15: Fill The System With Water And Establish Dilute Flow
Before E-Cell Stacks™ start, check: 1. All Valves are closed 2. All pumps are in the “OFF” position 3. DC power is turned “OFF” 4. Safety equipment is installed and operational. 8.2.1 Fill the system with water and establish Dilute Flow 1. -
Page 16: Establish Concentrate, Electrode, And Dilute Flow
9. Once water flows continuously through the Concentrate Bleed (no bubbles), prime the Concentrate Pump (see pump manufacturer’s instructions in Vendor Data). 8.2.2 Establish Concentrate, Electrode, and Dilute Flow 1. Throttle Concentrate Inlet Valve, so that it is 10-20% open. 2. -
Page 17: Confirm All Flows And Pressures
8.2.3 Confirm all flows and pressures 1. Electrode flow is 0.35 gpm/Stack (80 l/h). 2. Dilute Flow is 7.5-20.0 gpm/ 1.70-4.54 m /h per MK-2E, MK-2Pharm or MK-2PharmHT Stack™; 2.5-6.7 gpm/0.57-1.52 m /h per MK-2Mini or MK-2MiniHT Stack™. 3. Concentrate Bleed Flow is set for the appropriate recovery. 4. -
Page 18: Shut Down Procedures
SHUT DOWN PROCEDURES E-CELL STACK™ SHUT DOWN FROM AUTOMATIC OPERATION If the system is to be shut down for a period of time, and the piping configuration allows the system to drain, some of the manual valves must be closed. They include the following 1. -
Page 19: Operating Instructions
10. OPERATING INSTRUCTIONS 10.1 FLOW RATES There are four separate flow streams on the E-Cell System™ each with a distinct range and purpose. 10.1.1 Dilute Stream Range 7.5-20.0 gpm / 1.70-4.54 m /h per MK-2E, MK-2Pharm or MK-2PharmHT Stack™ 2.5-6.7 gpm / 0.57-1.52 m /h per MK-2Mini or MK-2MiniHT Stack™... -
Page 20: Concentrate Bleed Stream
In order to prevent the Concentrate stream from exceeding the solubility limits, a small amount of Concentrate is sent to drain. This water is replaced with Dilute feed water, through the Concentrate Make-up valve. The amount of Concentrate Bleed required is dependent on the Recovery required, which is itself dependent on the flow rates and the feed water hardness level. -
Page 21: Electrode Stream
Dilute Product Flow Recovery x100% Dilute Product Concentrat Bleed Electrode Outlet Flow Therefore, Dilute Product Flow − Concentrat Bleed Flow Electode Outlet Flow Dilute Product Flow Recovery Example For a system with <0.1 ppm of hardness in the feed water, 25 gpm Dilute Product flow and 0.5 gpm Electrode Outlet flow, what is the minimum Bleed flow rate? ... - Page 22 between the Concentrate Inlet and Dilute Inlet. The Concentrate By-pass valve controls the outlet pressure difference. Closing the valve decreases the Concentrate outlet pressure and thereby increases the pressure difference between the Concentrate outlet and Dilute outlet. The maximum E-Cell™ Dilute Feed water pressure is 100 psi (6.8 bar) PRESSURE DIFFERENCE BETWEEN DILUTE AND CONCENTRATE rev.1.1...
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Page 23: Operating Data
10.3 OPERATING DATA The E-Cell System requires little maintenance, however it is important to keep accurate ™ operating data. This should be used to track the performance of the system and help identify any problems as early as possible. The following parameters should be recorded at least once a day: •... -
Page 24: Preventative Maintenance
11. PREVENTATIVE MAINTENANCE 11.1 GENERAL Maintenance personnel must exercise extreme caution as any leaking water may be electrically charged Check high voltage connection and grounding wires are tight every 3 months. Do not externally clean E-Cell Stack™ using high pressure water. Check for proper recovery ratio once per week (minimum). - Page 25 Cleaning Procedure PROBLEM C, E chamber metallic scaling D, C, E chamber metallic scaling Organic fouling Organic fouling and metallic scaling Biological fouling Biological fouling and metallic scaling Heavy biological fouling Heavy biological fouling and metallic scaling Severe biological fouling Severe biological fouling and metallic scaling...
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Page 26: Safety
The Long Term Shutdown procedure must be followed if the E-Cell System is to be down for ™ more than three days. 11.2.2 Safety 1) Avoid contact with Halane (1,3-Dichloro-5,5-dimethyl hydantoin), sodium hydroxide, peracetic acid, hydrogen peroxide and hydrochloric acid, as these are corrosive. Hydrogen peroxide is an oxidizer. - Page 27 Cleaning Setup • Isolate the E-Cell system from upstream and downstream by closing the E-Cell System Dilute Feed Inlet, Dilute Product Outlet, and Dilute Rinse Outlet valves. • Connect the cleaning skid discharge to the E-Cell Dilute Feed Inlet cleaning connection. •...
- Page 28 Instruction 4: Peracetic Acid / Hydrogen Peroxide Solution Recirculation (Mild Oxidizing Sanitization/Cleaning) • Drain the cleaning skid and E-Cell skid. • Make up 25 L per Stack of peracetic acid 0.04% / hydrogen peroxide 0.2% solution (0.25 L of a commercial solution such as Minntec Minncare, Henkel-Ecolab Oxonia Active, Diversey Divosan, or FMC Flocide, in 25 L of water.) •...
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Page 29: Cleaning Procedures
11.4 CLEANING PROCEDURES Cleaning Procedure 1: Hydrochloric Acid Cleaning of Concentrate and Electrode Chambers This procedure provides an acid cleaning of the Concentrate and Electrode (anode and cathode) chambers of the Stacks to clean hardness and other metallic scale. Steps Cleaning Setup –... -
Page 30: Cleaning Procedure 4: Hydrochloric Acid And Sodium Chloride / Sodium Hydroxide Cleaning/Sanitizing
Cleaning Procedure 4: Hydrochloric Cleaning Procedure 5: Halane or Acid and Sodium Chloride / Sodium Peracetic Acid Sanitizing Hydroxide Cleaning/Sanitizing This procedure provides an acid cleaning of all Halane, a widely used source of chlorine, is chambers of the Stacks to remove inorganic useful for cleaning and sanitizing high-purity metallic scale. -
Page 31: Cleaning Procedure 8: Hydrochloric Acid And Halane Or Peracetic Acid Sanitizing And High Ph Sanitizing
Cleaning Procedure 8: Hydrochloric Acid and Halane or Peracetic Acid Sanitizing and High pH Sanitizing Where hardness or other metallic scale is present along with heavy biological fouling an acid cleaning step is added to the beginning of the procedure. Halane, a widely used source of chlorine, is useful for cleaning and sanitizing high-purity water treatment equipment.
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