PUT YOUR COMPANY NAME &LOGO HERE
WATER SOFTNER
Operational manual
Contract No ------------ Date --------
Client’s Name ----------------------------------------------------
XYZ Water Treatment Company
307 Gupta chambers
New community centre
New Delhi-110005
Delhi
Telephone : -0000000 / 0000000
Fax No 011 0000000
Email Web
1
TABLE OF CONTENTS
PROCESS...............................................................................................................................................................3
TECHNICAL DATA SHEET.................................................................................................................................4
DOWNFLOW SOFTNER......................................................................................................................................5
UPFLOW SOFTNER..............................................................................................................................................6
QUALITY OF WATER FROM SOFTNER.........................................................................................................9
TROUBLE SHOOTING OF SOFTNER..............................................................................................................10
METHOD OF TESTING HARDNESS................................................................................................................12
ROUTINE MAINTENANCE...............................................................................................................................15
2
Chapter 1
Basic Process
1.0 Introduction
Softening by ion exchange resin is also known as base exchange softening . It is the
Most common and probably the easiest method of removing hardness (that is calcium &
magnesium) from water and render the water suitable for utility purpose.
As the name implies ion exchange is a process in which undesirable ions are exchanged for
more desirable ions .
1.1 Process
The softening process consists of passing raw water containing hardness through a bed of
cation resin in sodium form . the hardness ions Ca & Mg are taken up by resin and in
exchange sodium ions are relinquished from the resin . Raw water will continue to get
softened till the resin gets exhausted. Bringing back the resin to it original form is called
regeneration . softener resin is regenerated by sodium chloride of 10—15 %
Concentration
1.2 Steps of operation for Downflow units
1) Backwash :- Backwashing by upward flow expands the bed and releases dirt so that
dirt can be discharged to waste.
2) Brine injection :- Common salt (brine) which is the regenerant is injected into the
softener and flows downwards (n the same direction of service flow) through the resin
bed . This type of regeneration is called co current or co flow regeneration.
3) Rinse :_ Brine injection is followed by water which displaces the brine downwards and
rinses the bed . The rinse water flushes and rinses the adhering brine from the resin bed
eluting the calcium & magnesium ions to waste.
1.3 Steps of operation for upflow units
1) Brine Injection :- The brine is injected to bed in downward direction but the service flow
is upwards . In regeneration where the direction of injection flow is opposite service
flow, the regeneration system is known as counter current or counter flow regeneration.
2) Slow rinse :- Slow rinse is given in the same direction as regeneration and the flow rate is
also the same. This is done to flush out the excess brine.
3) Fast Rinse:- Fast rinse is carried out in the direction of service flow that is upwards
Service
Ca (HCO3)2 Ca NaHCO3
SO4 + Na2 R R + Na2 SO4
Mg Cl2 Mg NaCl
Regeneration
Ca CaCl2
R + NaCl Na2 R +
Mg Mg
3
Technical Data sheet
Unit dia in mm
Unit dia in meters
Area
Bed depth
Unit HOS in meters
Resin volume in M3
kg of salt required
Hardness
OBR
Min. treatment flow M3/hr
Max. treatment flow M3/hr
Period between regn
Normal Flow M3/hr
Regn flow M3/hr
Slow rinse flow M3/hr
Fast rinse flow M3/hr
Minimum pressure kg/cm2
Maximum pressure kg/cm2
4
Chapter 2
Operation of softener
2.1 Startup of Downflow unit
2.1.1 Service
1) Open inlet valve V1 and air release valve V6
2) Close V6 once water starts coming from V6
3) Open V5 and rinse the unit for 5 minutes
4) Check for hardness and if satisfactory open outlet valve V2.
5) The unit is now in service
2.1.2 Regeneration
After the unit has given specified quantity of treated water , it has to be regenerated.
Backwash
Open V3 & V4 . After 10 minutes close V3 & V4. Once should be
careful with this operation because resin can escape if flow rate is very high.
Injection
Required quantity of common salt is taken in brine measuring tank and water is added to
make a brine solution of 30%
1) Open power water valveV7 and open Drain valve V5
2) Slowly open Suction valve V8 and the brine should be injected in 20- 40 minutes
3) Close V8 and all water to pass trough for some time to flush out the pipeline.
4) Close V7 & V5
Final rinse
Open V1 and Valve V5 and after 20 minutes start checking the quality of water and if
satisfactory close valve V5 and open V2 to take the unit into service
INLET TO SOFTNER
V1 V4
V8
SOFTNER
V3 V2
Outlet
V5
V7
Brine
Tank
5
2.2 Startup of upflow unit
Service
1) Open Inlet Valve V1 and rinse Valve V4
2) Check the quality water at the outlet of V4 and if satisfactory open V2 & close V4
3) The unit now is in service
Regeneration
1) Open power water Valve V5 and Drain Valve V3
2) Open Brine injection valve V6 in such a way that the brine is injected in 20—40minutes
Slow rinse
1) After the brine has been injected close Brine suction Valve V6. After 20—40minutes
Close V5 & V3
Final Rinse
1) Open V1 and V4
2) Check the quality of water from the unit at the outlet of V4.
3) If satisfactory close V4
4) If the unit has to be taken for service open V2 or close the pump
V2
5)
Regeneration line
V6
SOFTNER V4
Brine
Tank V5
V1 V3
6
Chapter 3
Treated water Quality
3.1 Softening (SAC Resin in Sodium Form)
Softening is the process used for removal of hardness. The feed water containing hardness is
passed through the sodium form Cation resin. Calcium and magnesium both being
divalent displace the monovalent sodium and gets attached to the resin. The treated water
coming out of the unit contains the Na ions which has been displaced by Ca and Mg.
As more and more untreated water passes the unit the resin goes on getting converted to Ca
and Mg form. The selectivity of resin for divalent compound is more than that for
monovalent ion. Higher molecular weight ion is preferred if both ions are of same valence.
Ca ions having higher molecular weight is preferred over Mg ions and thus displaces the
Mg ions further down the resin bed. Thus the top of the resin is enriched with Ca ion. Ca
ions pushes the Mg ions down the column which in turn pushes the Na ions. This cycle
continues till the hardness starts leaching out of the unit. This is known as Exhaustion.
The ions which appears first at the end of service cycle is predominantly is Mg ions.
Being dependent on flow rate and uniformity of flow distribution the band may not be
totally distinct.The effluent hardness is less than 5 ppm for low TDS water but is about 1%
of the total influent hardness in a co-flow regenerated unit depending upon the
regenerant level.
3.1 Quality of Effluent
All values are in ppm as CaCO3
Total Cation Raw water Sodium Guaranteed effluent Hardness
1000 100 <15ppm
800 <15ppm
1500 200 <50ppm
500 <50ppm
1000 <60ppm
2000 300 <80ppm
600 <80ppm
1000 <100ppm
2500 500 <100ppm
1000 <100ppm
1500 <140ppm
500 <150ppm
2000 <200ppm
7
Chapter 4
Troubleshooting Softener
Problem Cause Action
Loss of Capacity Increase in raw water Increase Brine, add more
hardness. Change in Na/Ca resin if possible (Not
ratio possible in up flow Packed
bed system) check
Over exhaustion of unit in Normal regeneration does
previous run not Restore capacity, use
double regeneration, adjust
end of run
Fouling with iron, Check raw water analysis,
manganese or aluminum give acid wash to resin (In
Fouling with dirt, mud etc separate Vessel if the unit is
not rubber lined). Give
extended backwash and
check for proper working of
pretreatment
Resin life Consult supplier, recharge if
resin is very old Loss of 5%
per year in capacity is
considered normal.
Poor distribution channeling Check pretreatment, flow
short circuiting rate too low, check for
broken distributor plugged
distributor
Poor quality of treated water Valve leakage Check backwash inlet valve
Close all valve and see the
PG. Increase in pressure
indicates that inlet valve is
passing, See that inlet valve
is passing, See valves.
Flow rate too high Contact time not sufficient
Reduce flow rate
Low flow rate Check in “Loss of Capacity”
Poor distribution. Run at
higher flow rate.
Unit idle Do not keep plant idle. If
water requirement is less
recycle water from unit.
Fouled resin Check and clean with acid.
Low temperature Rare in Indian condition Rate
of reaction slow
Dirty resin Give extended Backwash
periodically give open
manhole backwash.
8
Chapter 5
Water Analysis
5.1 Hardness
Hardness is defined as a soap consuming capacity of water. Hardness is mainly due to
presence of calcium and magnesium salts. There are two kinds of hardness – Temporary and
Permanent. Temporary hardness also called carbonate hardness is due to presence of
carbonates and bicarbonates. Permanent hardness is mostly due to chloride, sulphate and
nitrates.
5.2 Method
EDTA forms a chelated soluble complex when added to a solution of certain metal ions if
EBT(Erichrome Black TRIGGER) is added to water containing hardness the colour of the
solution turns wine red. This solution when titrated with EDTA will complex all the calcium
and magnesium and when this happens the colour turns blue from Red wine. The point at
which colour change takes place is known as END POINT.
5.2.1 Reagents
1. Ammonia Buffer Solution
2. 0.01M Solution of EDTA
3. Erichrome Black T indicator.
5.2.2 Apparatus required
1. Burette
2. Graduated cylinder
3. Conical flask (Erlenmeyer Flask)
4. Wash bottle
5. Distilled water
5.2.3 Procedure
Step -1 : Take 50ml of sample in an Erlenmeyer
Step -2 : Add 2ml of Ammonia buffer solution.
Step -3: Add 3 to 5 drops or ½ tablet of Erichrome black T indicator.
Step -4: The color becomes wine red
Step -5: Immediately titrate against EDTA solution.
Step -6: Carry on titration till the end point is reached i.e. when the color changes to blue.
5.2.4 Calculation
Volume of 0.01 EDTA Solution
Total Hardness as CaCO3 = ------------------------------------------------- X 1000
(mg/liter) Ml of sample
The permanent hardness is found by boiling the water. IT is cooled and then above
procedure repeated. Temporary hardness is given by the difference of two readings.
9
5.2.5 Interference
If bicarbonate exceeds 250 PPM it is advisable to add 1ml of 2N HCL before adding the
buffer solution. Any other metal ions chelating with EDTA can interfere with the result
provided they are in excess then mentioned below
Al++ > 20ppm, Cu++ > 20ppm, iron (Fe++ or Fe+++) > 10 PPM PO3 >
25ppm.
5.3 Calcium Hardness
The water sample is titrated against EDTA solution using MUREXIDE INDICATOR
(Ammonium purpurate) in highly alkaline medium.
5.3.1 Reagents
1. 1N Sodium Hydroxide Solution
2. 0.01M Standard EDTA Solution
3. Murexide Indicator.
5.3.2 Apparatus required
1. Porcelain dishes 100ml capacity.
2. Burette 25 to 50ml
3. Pipettes
4. Stirring rods (Glass)
5. Graduated cylinder.
5.3.3 Procedure:
1. Prepare standard solution as described in chapter.
2. Prepare a color comparison blank in a porcelain dish. The dish should be of white color
2.0ml of IN NaOH and 0.2g (4 to 6 drops of indicator) solid indicator is added to 50ml
of distilled water with constant stirring 0.05 to 0.1ml of EDTA titrant is added to
produce unchanging purple color.
3. 50ml of sample solution is pipetted into similar white dish.
4. Add few drops of 0.02 N HCL to neutralize the alkalinity.
5. Boil for 2 to 3 minutes to expel CO2 and then cool to room temperature.
6. Add 20ml of 1N NaOH or volume sufficient to produce pH of 12 – 13 and mix.
7. Add 0.2gm of powdered indicator or 4 to 6 drops of solution.
8. Stirring constantly titrate with EDTA solution to the colour of comparison blank.
9. Add 1 to 2 drops of titrant in excess to be sure that no further deepening of colour takes
place.
5.3.4 Calculation
(A-B) X C X 1000
Calcium as ppm CaCO3 = -----------------------------
Ml of sample
Where A = ml of EDTA required for titration of sample.
B .= ml of EDTA required for titration of blank.
C = mg of CaCO3 equivalent to 1.0 ml of EDTA.
10
5.4 Magnesium Hardness
The difference between Total Hardness and Calcium Hardness is magnesium Hardness
Caution
Laboratory Testing should be done only by qualified personnel. The
person should verify the method before testing
11
Chapter 6
Routine Maintenance
6.1 Introduction
Inspect all units externally every six months including connecting pipe work and valves.
Chip away all loose paints and rust and repaint . Make sure that inlet & outlet valves are
closed when making internal inspection . before opening the manhole open air release valve
& Drain valve . Open manhole only after all water has been drained out.
Check rubber lining. If there is any hint of damage carry out spark test and rectify. If the
damage is suspected below the resin will have to be removed and damaged lining will have
to be removed . Once the damaged lining has been repaired recharge the resin back to vessel.
It is the best time to take a sample of resin for analysis . Simple analysis can be done at site
and for complete analysis can be done in any good laboratory.
Once the resin has been charged into vessel , an extended backwash is recommended.
See Extended backwash & airscour
After backwashing and draining note the bed level with reference to some convenient point.
See Bed Depth.
6.2 Air scour & Extended backwash
Ion exchange resin tends to break up after prolonged use under varying flow and pressure
condition. This is known as attrition loss ad is normally considered as 5% per Annum. This
fines if not removed tend to choke up the bed and increase the pressure drop across the bed .
Thus the flow through the unit is reduced. The fines on the top of bed gets removed in
normal backwash but some fines which go deep into the resin bed is not removed .To
remove these fines extended backwash or open manhole backwash is given. This step should
be carried out by responsible person at site because if flow is not controlled there is chances
of resin loss .This step is recommended once a year .
6.2.1 Equipment
1) An air hose of sufficient length to reach the bottom of the resin bed.The hose should be
weighed at and
2) Air supply at 0.5 kg/cm2
3) A plastic bucket to remove fines
6.2.2 Method
1) Open the back wash outlet valve
2) Open the manhole
3) Close the backwash outlet valve and open the rinse outlet valve.
4) Drain the water till level is about 300mm above the resin bed
5) Insert the air hose half way into resin bed taking care to see it does not reach the bottom
of the bed and disturb the under bed, if any.
6) Connect the hose to air supply and start the air.
7) Move the hose throughout the resin.
8) Continue this operation for fifteen minutes .
9) Cut off air supply and remove the air hose
10) Open back wash outlet valve and slowly open backwash inlet valve, taking care that
The effluent water does not carry good resin. See note
11) After the backwashing is over ,close the backwash inlet valve and backwash outlet valve
12) Open Rinse outlet valve and drain the water to slightly below the resin bed level .
12
13) Scrape off 6mm layer from the top of the resin bed and discard the fine resin .
14) Close the manhole cover
The unit is now ready for further use
Note-
1. The step 10 can also be carried out like this. Open backwash inlet valve in such a way
that water starts filling the vessel and then start coming out of manhole .The flow
should be controlled in such a way that only water flows and no resin escapes. The rest
of the steps are as above.
2. Use plastic or wooden ladder and make sure that it does not damage rubber lining and
internals
13
