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Technical Bulletin 6.17, Rev. 0 December 1998

Vessel Internals

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GRD2000 TECHNICAL SPECIFICATIONS


Technical Bulletin 6.17, Rev. 0 December 1998

Table of Contents
Section 1.0 2.0 3.0 4.0 Scope References Design
3.1 Internal Distributors and Collectors

Page
2 2 3 3 11 11 12 13 13 13 14 14 14 15 15 15

Materials of Construction
4.1 4.2 General Gaskets

5.0

Fabrication
5.1 5.2 5.3 5.4 5.5 Weld Procedures and Qualifications Cleaning, Surface Preparation and Cleanliness Filler Metal Polypropylene Fusion Process and Qualifications PVC Solvent Cementing Processes and Qualifications

6.0 7.0

Inspection, Examination and Testing


6.1 Dimensional Inspection

Preparation for Lining and Painting

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Technical Bulletin 6.17, Rev. 0 December 1998 1.0 Scope
This specification establishes the minimum requirements for the mechanical design, materials, fabrication, testing and inspection for vessel internals.

2.0 References
The latest edition or revision of the following references are part of this specification: American Society of Mechanical Engineers (ASME) Section II Material Specification Section IX Welding & Brazing Qualifications American National Standards Institute (ANSI) B1.1 Unified Inch Screw Threads B1.20.1 Pipe Threads B16.5 Pipe Flanges & Flanged Fittings B16.9 Steel Butt-Welding Fittings B16.11 Forged Steel Fittings, Socket-Welding & Threaded B16.21 Non-Metallic Flat Gaskets for Pipe Flanges B18.2.1 Square & Hex Bolts & Screws B18.2.2 Square & Hex Nuts B36.10 Welded & Seamless Wrought Steel Pipe B36.19 Stainless Steel Pipe American Society for Testing and Materials (ASTM) D-1784 Rigid PVC Compounds and CPVC Compounds D-1785 PVC Pipe, Schedules 40, 80 and 120 D-2241 PVC Plastic Pipe D-2464 Threaded PVC Plastic Pipe Fittings, Schedule 80 D-2467 Socket Type PVC Plastic Pipe Fittings, Schedule 80 D-2564 Solvent Cements for PVC Plastic Pipe and Fittings D-2657 Standard Practice for Heat Joining Polyolefin Pipe and Fittings D-2855 Making Solvent Cemented Joints with PVC Pipe and Fittings D-3036 PVC Plastic Line Couplings, Socket Type D-4101 Standard Specification for Polypropylene Plastic Injection and Extrusion Materials F437 Threaded CPVC Plastic Pipe Fittings, Schedule 80 F439 Socket Type CPVC Plastic Pipe Fittings, Schedule 80 F441 CPVC Plastic Pipe, Schedules 40 and 80 F493 CPVC Solvent Cement Manufacturers SP25 SP43 SP44 Standardization Society (MSS) Standard Marking Systems for Valves, Fittings, Flanges & Unions Wrought Stainless Steel Butt-Welding Fittings Steel Pipe Line Flanges

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Technical Bulletin 6.17, Rev. 0 December 1998 3.0 Design
3.1 Internal Distributors and Collectors 3.1.1 General All headers shall be flanged at one end and capped at the other end. All laterals shall be threaded at one end and capped at the other end. The flange and the cap shall be continuously welded. All removable internals shall be bolted in place with corrosion-resistant, continuously threaded metal studs, flat washers and double-hex nuts on each end of the stud. Headers and laterals shall be sized for a nominal linear velocity of 10 fps for liquids, and in no case shall it exceed 12 fps. When designing for gaseous distribution (pressurized air or nitrogen) a pressure drop profile shall be generated to ensure the assembly will not create an excessive pressure drop.

Figure 17-1: Typical Header and Lateral

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Technical Bulletin 6.17, Rev. 0 December 1998
3.1.2 Inlet Distributor The inlet distributor can be fixed or removable and shall be located in the top of the vessel. For flow rates up to 12 gpm/ft2 a multi-point design with a header and several risers branching off of the header can be used. The risers shall face the top of the vessel and shall be complete with flow deflectors to evenly distribute the service liquid at a low velocity (5 fps maximum). The metallic distributor assemblies shall be fabricated from sch 10 pipe. The PVC assemblies shall be fabricated from schedule 80 pipe and shall be limited to a maximum 6 NPS. The polypropylene assemblies shall be fabricated from 10 bar pipe and shall be limited to a maximum 6 NPS.

Figure 17-2: Standard Inlet Distributor For flow rates between12 gpm/ft2 and 35 gpm/ft2, a multi-point design with a header and several risers branching off of the header shall be used. The risers shall face the top of the vessel and shall be complete with perforated baskets to evenly distribute the service liquid at a low velocity (2.5 fps maximum). Only metallic distributor assemblies shall be used and they shall be fabricated from sch 10 pipe.

Figure 17-3: High Flow Inlet Distributor


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Technical Bulletin 6.17, Rev. 0 December 1998
For flow rates in excess of 35 gpm/ft2, a multi-point design with a hub, several distribution arms branching off of the hub and a perforated plate shall be used. The perforated plate shall be designed to evenly distribute the service liquid at a low velocity (2.5 fps maximum). Only metallic distributor assemblies shall be used and they shall be fabricated from sch 10 pipe.

Figure 17-4: Ultra-High Flow Inlet Distributor 3.1.3 Regenerant Distributors The downflow regenerant distributor shall be removable and shall be located just above the resin bed. It shall be a header-lateral design with a header extending the width of the vessel and several laterals branching off of the header. The laterals shall be threaded into couplings that are continuously welded to the header. Several holes sized for the specific design flow rate shall be drilled in the laterals to evenly distribute the regenerant liquid. The laterals shall be rigidly supported with removable structural steel members. If metallic, the header shall be fabricated from sch 10 pipe and the laterals from sch 40 pipe. If PVC or polypropylene, the header and laterals shall be fabricated from sch 80 and 10 bar pipe, respectively.

Figure 17-5: Downflow Regenerant Distributor

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Technical Bulletin 6.17, Rev. 0 December 1998
The upflow regenerant distributor shall be removable and shall be located below the false bottom. It shall be a header design that extends the width of the vessel. Several holes sized for the specific design flow rate shall be drilled in the header to evenly distribute the regenerant liquid. If metallic, the header shall be fabricated from sch 10 pipe. If PVC or polypropylene, the header shall be fabricated from sch 80 and 10 bar pipe respectively.

Upflow Regenerant Distributor

Figure 17-6: Upflow Regenerant Distributor 3.1.4 Interface Collectors, Subsurface Wash Distributors and Air Scour Distributors These assemblies shall be removable and shall be located in the resin bed. They shall be a header-lateral design with a header extending the width of the vessel and several laterals branching off of the header. The laterals shall be threaded into couplings that are continuously welded to the header. The laterals shall be sch 40 pipe with holes drilled on two sides of the pipe for the entire length of the pipe. Wellscreen with 0.007" slot size and with an outside diameter slightly smaller than the inside diameter of the pipe shall be welded into the pipe. The laterals shall be rigidly supported with removable structural steel members. The header shall be fabricated from sch 10 metallic pipe. The laterals shall be fabricated from sch 40 metallic pipe.

Subsurface Wash Assembly

Figure 17-7: Subsurface Wash Assembly


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Technical Bulletin 6.17, Rev. 0 December 1998
3.1.5 Draindown Laterals The draindown lateral shall be removable and shall be located just above the media bed. The lateral shall be of wellscreen construction with 0.007" slot size.

Figure 17-8: Draindown Lateral 3.1.6 Resin Fill and Resin Removal Headers The resin fill header shall be removable and shall be located above the resin bed. It shall be designed to direct the resin into the center of the vessel. The header shall be fabricated from sch 10 metallic pipe. The resin removal header shall be removable and shall be located at the bottom of the bed. It shall be designed to remove the resin from the center of the vessel. The header shall be fabricated from sch 10 metallic pipe.

Figure 17-9: Resin Fill Header and Resin Removal Header

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Technical Bulletin 6.17, Rev. 0 December 1998
3.1.7 Resin Sluice Assembly The resin sluice shall be removable and shall be located in the resin bed. It shall be a header-lateral design with a header extending the width of the vessel and several laterals branching off of the header. The laterals shall be threaded into couplings that are continuously welded to the header. The laterals shall be complete with spray nozzles. The laterals shall be designed to easily adjust the position of the nozzles. There shall be an adequate number of nozzles to ensure that the resin will be sluiced toward the resin removal outlet. The header shall be fabricated from sch 10 metallic pipe. The laterals shall be fabricated from sch 40 metallic pipe.

Resin Sluice Assembly

Figure 17-10: Resin Sluice Assembly 3.1.8 Flat Plate Underdrain The flat plate underdrain shall be a flow-through design that is welded into the vessel. The plate shall be designed to withstand 40 psi differential pressure. The flat plate and support structure shall be fabricated from carbon steel.

Figure 17-11: Flat Plate Underdrain


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Technical Bulletin 6.17, Rev. 0 December 1998
3.1.9 Underdrain Strainers Metallic underdrain strainers shall include a formed 16-gauge top cap, a section of wellscreen with 0.007" slot size, two 16-gauge formed bottom caps (one above the false bottom and one below the false bottom), and a 16-gauge formed T-bar. Plastic strainer assemblies can be combinations of many different parts, depending on their function. The strainer element shall have 0.008 slots. A locking nut shall be used to secure the strainer element in place. A counter flow valve shall be used in place of a retaining nut when bi-direction flow at different flow rates is required. The orifice in the counter flow valve shall be sized for each application to ensure proper flow distribution. When required, another strainer element can be used in place of the retaining nut. All components shall be fabricated from virgin polypropylene in applications not o exceeding 140 F and glass fiber reinforced polypropylene for applications o up to 230 F.

Plastic Strainer with Counter Flow Valve Plastic Strainer with Retaining Nut

Double Plastic Strainer Assembly

Metallic Strainer
Figure 17-12: Underdrain Strainer Assemblies

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Technical Bulletin 6.17, Rev. 0 December 1998
3.1.10 Hub-Radial Underdrain This type of underdrain Is typically installed in filtration units. It shall consist of a removable cylindrical hub in the center of the vessel. Top and bottom plates shall be continuously welded to the cylinder. Several threaded couplings shall be continuously welded into the side of the cylinder equally spaced around the circumference. There shall be one lateral threaded into each of the couplings that branch off of the side of the cylinder. The laterals shall be sch 40 pipe with holes drilled on two sides of the pipe for the entire length of the pipe. Wellscreen with 0.007" slot size, and an outside diameter slightly smaller than the inside diameter of the pipe shall be welded into the pipe. The underdrain shall be designed such that the entire vessel can be drained.

Hub-Radial Underdrain
Figure 17-13: Hub-Radial Underdrain

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Technical Bulletin 6.17, Rev. 0 December 1998 4.0 Materials of Construction
4.1 General All components shall conform to the chemical and mechanical requirements of referenced material specifications. All components shall conform dimensionally with the relevant ANSI Standard. The material of construction of the internal components may vary depending on the liquid that will come into contact with these parts as follows: Material Acceptability Chart

PVC Am i n e Hydrochloric Acid (5%) Sodium Chloride (10%) Sodium Hydroxide (4%) Sulfuric Acid (4%) A A A A

Polypropylene

Stainless Steel A

Hastelloy C

A A A A A A A

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Technical Bulletin 6.17, Rev. 0 December 1998
ASTM Material Designation 316L Stainless Steel Pipe ............................. ASTM A312 GRADE TP316L EFW Flange 150 lb. RF, SO ........ ASTM A182 GRADE F316L Fitting Socket Weld .......... ASTM A182 GRADE F316L Butt Weld .............. ASTM A 403 WP 316L Coupling 150 lb. threaded .... ASTM A351 GRADE CF8M Plate ............................. ASTM A240 GRADE 316L Bolt or continuously threaded stud ........ ASTM F593 GRADE 316 Hex Nut ....................... ASTM F594 GRADE 316 Hastelloy C Pipe ............................. ASTM B619 C-276 welded Flange 150 lb. RF,SO ......... ASTM B575 C-276 Fitting Socket Weld .......... ASTM B574 C-276 Butt Weld .............. ASTM B366 WPC276 Coupling 150 lb. threaded .... ASTM B574 C-276 Plate ............................. ASTM B575 C-276 Bolt or continuously threaded stud ........ ASTM B574 C-276 Hex Nut ....................... ASTM B574 C-276 4.2 Gaskets Unless otherwise noted all gaskets shall be fabricated from ethylene propylene (EPDM). Full-faced gaskets shall be used on flat faced flanges and ring gaskets shall be used on raised-faced flanges. All gaskets shall be 1/8" thick. The pressure rating of the gasket shall match that of the adjoining flange.

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Technical Bulletin 6.17, Rev. 0 December 1998 5.0 Fabrication
5.1 Weld Processes and Qualifications The following welding processes are acceptable: Submerged Arc Welding (SAW). Shielded Metal Arc Welding (SMAW). Gas Tungsten Arc Welding (GTAW) with an inert shielding gas. Gas Metal Arc Welding (GMAW) with an inert shielding gas.

All welding shall be performed by qualified welders using qualified welding procedures. Welders, welding operators and welding procedures shall be qualified in accordance with ASME Section IX. Welding procedure specifications (WPS) and procedure qualifications (PQR) shall be available for review upon request. 5.2 Cleaning, Surface Preparation and Cleanliness All surfaces to be welded shall be cleaned and free of moisture, paint, oil, grease, rust, scale or other material that would be detrimental to either the weld or base metal under welding conditions. Each layer of weld metal of multipass welding shall be thoroughly cleaned of slag and other deposits before applying the next pass. Peening is not permitted. Surface preparation for welds is acceptable only if the surface is reasonably smooth and true. Take suitable precaution to protect cleaned surfaces from contamination after cleaning until welding is complete. NOTE: Tools that have been used to cut or clean carbon or iron components shall not be used on stainless steel. All stainless steel that has been contaminated with carbon steel debris shall be thoroughly cleaned with pickling paste.

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Technical Bulletin 6.17, Rev. 0 December 1998
5.3 Filler Metal The filler metal shall have similar chemistry, corrosion resistance and mechanical properties of the base metal being welded. The filler metal shall conform to ASME Section II, Part C. 5.4 Polypropylene Fusion Processes and Qualifications All socket and butt fusion type polypropylene components shall be joined in accordance with ASTM D2657. The operator shall be factory-trained and certified in accordance with the manufacturers written procedures. All fusion joints shall be made in accordance with the manufacturers recommendations for fusion temperature, joining pressure, alignment and fusion time. The cut ends of pipe must be square and cleaned inside and outside of all burrs, dirt, grease and moisture. 5.5 PVC Solvent Cementing Processes and Qualifications All solvent cemented components shall be joined in accordance with ASTM D2855. The operator shall be factory trained and certified in accordance with the manufacturers written procedures. All cemented joints shall be made in accordance with the manufacturers recommendations. The cut ends of pipe must be square and cleaned inside and outside of all burrs, dirt, grease and moisture.

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Technical Bulletin 6.17, Rev. 0 December 1998 6.0 Inspection, Examination and Testing
6.1 Dimensional Inspection All internals shall be inspected to ensure that all dimensions have been held within tolerance. Unless otherwise noted, the tolerance on all dimensions shall be 1/8".

7.0 Preparation for Lining and Painting


All vessel surfaces shall be cleaned to remove loose scale, rust, grease, dirt, weld spatter and other foreign matter. All welds must be smooth with no porosity, holes, high spots, lumps or pockets. All corners and all weld seams are to be ground to a minimum radius of 1/8".

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