Water Purification System for a Laboratory Facility

Water Purification System for a Laboratory Facility
Millipore Corporation Bioscience Division Christopher Yarima Mike Kelly

Outline Contaminants in Water
Pure Water Applications and Quality Standards Water Purification Technologies Key Water Purification System Design Steps Systems Questions

Water Chemistry – Contaminants

Ground & Surface Water Surface Water Ground Water
Lower in dissolved ions Higher in organic materials Higher in particulates - Higher in biological material Ground Water Higher in dissolved ions Lower in organic materials Lower in particulates - Lower in biological Material Basic water contaminants can be broken down into 4 categories. Should briefly go over the different contaminants.

Contaminants in Potable Water
Inorganic Ions Cations Na+ Ca+2 Anions Cl- HCO-3 Organics Natural Tannic Acid Humic Acid Man Made Pesticides Herbicides Particles (Colloids) Non Dissolved Solid Matter (Small deformable solids with a net negative charge) Microorganisms (Endotoxin) Bacteria , Algae , Microfungi (Lipopolysaccharide fragment of Gram negative bacterial cell wall) H H H-C-C-OH Basic water contaminants can be broken down into 4 categories. Should briefly go over the different contaminants.

Measurement of Contaminant level
Endotoxin units/ml Rabbit Inoculation test LAL Test Endotoxin cfu/ml Colony count on 0.45 μm membrane. Bacteria Rate of pluggage of 0.45 μm membrane. Silt Density Index / Fouling Index Particles (Colloids) ppb (μg/L) Total Oxidizable Carbon (T.O.C.) Organics μs/cm MΩ.cm Conductivity (Resistivity) Inorganic Ions Unit Measurement Contaminant

Measurement Units Thickness of a Human hair = 90 microns
Smallest visible particle = 40 microns 1 Micron = 10-6 Meters Smallest bacteria = 0.22 micron ppm : Parts per Million = mg/Liter ppb : Parts per Billion = microgram/Liter ppt : Parts per Trillion = nanogram/Liter 1 ppb = 1 Second in 32 Years. !!!

Water Standards

Standards and Common Terms
Ultrapure/Reagent Grade Critical Applications Water for HPLC,GC, HPLC ,AA , ICP-MS, for buffers and culture media for mammalian cell culture & IVF, reagents for molecular biology... “Ultrapure” Type 1 Pure/Analytical Grade Standard Applications Buffers, pH solutions,culture media preparation ,clinical analysers and weatherometers feed. Type II “Pure” Millipore has broken purified water down into 3 categories. The categories should each be targeted at different applications. Pure/Laboratory Grade General Applications Glassware rinsing, heating baths, humidifiers and autoclaves filling Type III

Laboratory Water Purity Specifications Consolidated Guidelines
Regulatory Agencies with Published Standards: ASTM: American Society for Testing and Materials CLSI: Clinical and Laboratory Standards Institute (previously NCCLS: National Committee for Clinical Laboratory Standards) CAP: College of American Pathologists ISO: International Organization for Standardization USP: United States Pharmacopoeia EU: European Pharmacopoeia There are several organizations, or agencies with detailed published standards for each of the water quality types. These key agencies are listed at the bottom of the slide, ASTM, NCCLS, CAP for example. When you look at each of these standards they are quite similar, but each with there own small differences. To simplify Millipore has consolidated and summarized these standard into these Millipore standard guidelines. (If someone asks for the details of some of the standards hand them out or offer to send them later. Try not to spend too much time reviewing the details of the standards.) In the design process it is important to define as detailed as possible the water quality needed throughout the lab. This might be ASTM in a university research area or NCCLS in a hospital. It is quite often that the clients or end users do not know what specific water quality is required. We have been in situations where when we ask what water quality is needed we get a response of “real pure”. Even when we ask for more detail we’ve gotten responses that we need “really really pure” or “the best water you can make”. These are difficult to design to and can lead to issues after commissioning when researchers start using the water. In these cases Millipore has experience with many different applications for water and can help work with the A&E firm and the final end uses to define clear water quality requirements.

ASTM Standards for Laboratory Reagent Water
There are several organizations, or agencies with detailed published standards for each of the water quality types. These key agencies are listed at the bottom of the slide, ASTM, NCCLS, CAP for example. When you look at each of these standards they are quite similar, but each with there own small differences. To simplify Millipore has consolidated and summarized these standard into these Millipore standard guidelines. In the design process it is important to define as detailed as possible the water quality needed throughout the lab. This might be ASTM in a university research area or NCCLS in a hospital. It is quite often that the clients or end users do not know what specific water quality is required. We have been in situations where when we ask what water quality is needed we get a response of “real pure”. Even when we ask for more detail we’ve gotten responses that we need “really really pure” or “the best water you can make”. These are difficult to design to and can lead to issues after commissioning when researchers start using the water. In these cases Millipore has experience with many different applications for water and can help work with the A&E firm and the final end uses to define clear water quality requirements. ASTM: American Society for Testing and Materials

CLSI*, water quality specifications CLSI guidelines should be read to understand scope and detail for each requirement CLRW; Clinical Laboratory Reagent Water SRW; Special Reagent Water CLRW water quality with additional quality parameters and levels defined by the laboratory to meet the requirements of a specific application For example: CLRW quality with low silica and CO2 levels Instrument Feed Water Confirm use of CLRW quality with manufacturer Water quality must meet instrument manufacturers specifications Also defined: Commercially bottled purified water, autoclave and wash water and water supplied by a method manufacturer (use as diluent or reagent) There are several organizations, or agencies with detailed published standards for each of the water quality types. These key agencies are listed at the bottom of the slide, ASTM, NCCLS, CAP for example. When you look at each of these standards they are quite similar, but each with there own small differences. To simplify Millipore has consolidated and summarized these standard into these Millipore standard guidelines. In the design process it is important to define as detailed as possible the water quality needed throughout the lab. This might be ASTM in a university research area or NCCLS in a hospital. It is quite often that the clients or end users do not know what specific water quality is required. We have been in situations where when we ask what water quality is needed we get a response of “real pure”. Even when we ask for more detail we’ve gotten responses that we need “really really pure” or “the best water you can make”. These are difficult to design to and can lead to issues after commissioning when researchers start using the water. In these cases Millipore has experience with many different applications for water and can help work with the A&E firm and the final end uses to define clear water quality requirements. *CLSI: Clinical and Laboratory Standards Institute (previously NCCLS)

US and European Pharmacopoeia Pure Water
Purified and Highly Purified Water* USP Purified EU Purified EU Highly Purified Conductivity: <1.3 uS/cm at 25oC <4.3 uS/cm at 20oC <1.1 uS/cm at 20oC TOC: < 500 ppb < 500 ppb <500 ppb Bacteria: <100 cfu/ml <100 cfu/ml <10 cfu/100 ml Endotoxin: N/A N/A <0.25 EU/ml * Overview of USP28 and EP 4th edition, (refer to detailed specifications for exact norms).

Purification Technologies
Overview of Key Technologies Advantages/Disadvantages Summary

Filtration – Depth and Screen Filters Activated Carbon and chlorine removal Mineral scale control – Softening and Sequestering Distillation Reverse Osmosis Deionization Electrodeionization Ultraviolet light

Depth & Screen Filters Glass Fiber SEM Durapore Membrane - SEM Depth filters = matrix of randomly oriented fibers in a maze of flow channels. Screen filters = rigid, uniform continuous mesh of polymeric material with pore size precisely determined during manufacture. 2 types of filters: depth & screen (or membrane) filters. Depth filters : for RO protection from fouling (high particle capacity). Membrane filters : for retention of small amounts (quick clogging) of small particulates like bacteria. Additional treatment: Depth filters : for heavily loaded feed water with particles (SDI over specification). Screen filters : for a final low pore size filtration downstream the system. Charge filters : for pyrogen removal, in-line distribution loop Compare depth and screen filters. Depth filters better for pretreatment because of their large capacity. Not as accurate for bacterial removal because they do not have a maximum pore size. A good example of a screen filter in everyday life is a coffee filter. It stops almost all of the coffee grinds, but every once in a while a few of the grounds get through. Advantages..typically very high dirt retaining capacities, good chemical resistance characteristics Many options in size exclusions, materials of constructions Disadvantages…depth can shed/add particulate, pressure/flow can damage media cause bypass.

Filtration Summary Depth Filters Random Structure Nominal retention rating Works by entrapment within “depths” of filter media High “dirt” holding capacity Screen/Membrane Filters Uniform Structure Absolute retention rating Works largely by surface sieving Low dirt holding capacity

Activated Carbon Granules or beads of carbon activated to create a highly porous structure with very high surface area Activation can be heat or chemical Pore sizes typically <100 to 2000 Å Surface area typically 500 to >2000 m2/gram Removal of organics by adsorption Removal of chlorine by adsorption-reduction

Mineral Scale Control Ca++ + CO3= CaCO3 CO3= Ca++ (S)
Calcium and carbonate ions are common in tap water supplies Scale forms when concentration exceeds solubility limits and CaCO3 precipitates as a solid Higher concentrations increase risk of scale formation Higher pH and higher temperature increase risk of scale formation Important in domestic water systems and purification technologies CO3= Ca++ Ca++ + CO3= CaCO3 (S) Calcium carbonate scale

Scale Control – Ion-exchange Softening
"Hard water" Cation Exchange Resin Ca Cl- Mg Cl- R Na Na R R Na Na R R Ca R R Mg R 4 Na+ + 4 Cl- "Soft water"

Scale Control Ion-exchange Softener Regeneration
Regenerated resin R Na Na R Na+ Cl- R Na Na R R Ca R conc. NaCl R Mg R Mg CL- Ca Cl- EXCESS Na+ Cl- Exhausted resin Softeners are regenerated using a concentrated “brine” flush

Scale Control – Chemical Sequestering
Chemical sequestering “weakly binds” calcium ion preventing calcium and carbonate ions from forming scale Liquid and solid chemical options available Solid polyphosphate shown as example illustration CO3= Ca++ Ca++ + CO3= CaCO3 (S) _ Polyphosphate chain

Double Distillation Principal
Benefits Removes wide class of contaminants Bacteria / pyrogen-free Low capital cost Heat to vapor Recondense by cooling vapor Cooling water jacket Limitations High maintenance High operating cost Low resistivity Organic carryover Low product flow High waste water flow Water storage Distillation is not a technology that Millipore uses. It is capable of removing a wide range of contaminants. However, it is very costly to run, in both electricity and water requirements. Stills also require a lot of maintenance. Some organics/volatile have bp lower than water and will carry over regardless of this method.

= 1 psi of osmotic pressure
Natural Osmosis Pure water will pass though the membrane trying to dilute the contaminants Osmotic Pressure Water Plus Contaminants Pure Water Semi-Permeable ~100 ppm NaCl = 1 psi of osmotic pressure Reverse Osmosis Membrane

Reverse Osmosis Reject Pressure Water Plus Contaminants Pure Water
Pressure applied in the reverse direction exceeding the osmotic pressure will force pure water through the membrane A reject line is added to rinse contaminants to drain Pressure Water Plus Contaminants Pure Water Semi-Permeable Reject Reverse Osmosis Membrane

Reverse Osmosis Summary
Limitations Not enough contaminants removed for Type II water. RO membrane sensitivity to plugging (particulates), fouling (organic,colloids), piercing (particle, chemical attack) and scaling (CaCO3) in the long run if not properly protected. Need of right pressure (5 bars) & right pH for proper ion rejection. Flow fluctuation with pressure and temperature. Membrane sensitivity to back pressure Preservative rinsing needed Need optimized reject Benefits All types of contaminants removed: ions, organics - pyrogens, viruses, bacteria, particulates & colloids. Low operating costs due to low energy needs. Minimum maintenance (no strong acid or bases cleaning) Good control of operating parameters. Ideal protection for ion-exchange resin polisher: a large ionic part already removed (↑ resin lifetime), particulates, organics, colloids also eliminated (no fouling). The key benefit to RO is its ability to remove a wide range of contaminants. RO membranes also have a very low operating costs. Our systems use less electricity than a standard light bulb. The limitations in a traditional RO system is the loss of production as feed water temperature drops (note here that in our systems we have solved this problems). Even though a wide range of contaminants is removed the removal efficiency is not high enough to produce Type II water.

Ion Exchange Benefits Limitations R - SO-3 H+ + Na+ R - SO-3 Na+ + H+
IX resin (+) Ion (-) Particulate Colloid (-) Organics Fines (-) R - NH4OH- + Cl R - NH4 Cl OH- R - SO-3 H+ + Na R - SO-3 Na+ + H+ Cation Exchange Resin Anion Exchange Resin H2O Benefits Effective at removing ions  Resistivity 1-10 MΩ.cm with a single pass through the resin bed.  Resistivity 18 MΩ.cm with proper pretreatment Easy to use: Simply open the tap and get water Low capital cost Limitations Limited or no removal of particles, colloids, organics or microorganisms Capacity related to flow rate and water ionic content Regeneration needed using strong acid and base Prone to organic fouling Multiple regenerations can result in resin breakdown and water contamination Risk of organic contamination from previous uses Explain how Ion-Exchange works. This background will be necessary to explain the advantages of EDI. Anion and Cation Exchange resins bind cations and anions and release either hydrogen or hydroxide. When all of the binding sites on the resin have been used then the resin is exhausted. It is very effective at removing ions to produce either type II or type I water. The limitations of traditional ion-exchange is that quality will lfuctuate over the life of the resin. When resins are exhausted they can release organic compunds. In make-up system regenerated resins are typically used. Regenerated resins can also tend to release fines or small particles as they degrade.

Electrodeionization (EDI, CDI, ELIX, CIX)
Conductive Carbon Beads A C Na + H OH - Cl- Na+ Cl Waste Product RO Feed Water Ion Exchange Resin Continuous deionization technique where mixed bed ion-exchange resins, ion-exchange membranes and a small DC electric current continuously remove ions from water (commercialize by Millipore in mid 80’s) Performance enhancements: Ion-exchange added to waste channels improve ion transfer and removal. Conductive beads aded to cathode electrode channel reduces risk of scale and use of a softener EDI is Millipore’s improvement on ion-exchange. A small electrical current is continuously run across ion-exchange resins to regenerate them. Produces a very consistent water quality b/c resins are not exhausted in the purification process. Cations driven toward negative electrode by DC current Anions driven toward positive electrode by DC current Alternating anion permeable and cation permeable membranes effectively separate ions from water RO feed water: Avoids plugging, fouling and scaling of the EDI module

Electrodeionization Benefit Limitations
Very efficient removal of ions and small MW charged organic (Resitivity > 5 MΩ-cm) Low energy consumption Typical <100 watt light bulb High water recovery No chemical regeneration Low operating cost Low maintenance No particulates or organic contamination (smooth, continuous regeneration by weak electric current) Limitations Good feed water quality required to prevent plugging and fouling of ion-exchange and scaling at cathode electrode RO feed water ideal New enhancements minimize risk of scale. Weakly charged ions more difficult to remove Dissolve CO2 and silica Moderate capital investment B/c of our focus on Elix technology go over all of the benefits of the technology. When going over the limitations mention that we have ensured that a high quality RO water is used to feed systems, by building our own RO/EDI systems to integrate both technologies.

UV Light Wavelenght (nm)
UV Lamps (254 and 185 nm) 3 O2 2 O3 2 O2 + 2 O * UV (185 ) UV (254) 4 OH * H2O 2 H2O CH3OH 2 OH * HCHO 2 H2O HCOOH CO2 100% 80% 60% 40% 20% 0% 240 260 280 300 320 254nm Relative Bactericidal Effect UV Light Wavelenght (nm) The UV rays between 200 and 300 nm destroy the micro-organisms by breaking the DNA chains. The optimal wavelength for DNA damage is 260 nm. 254 nm radiation is quite close to the optimum germicidal action efficiency (about 80%) and can therefore be successfully used to destroy bacteria. 254 UV does not oxidize organics Focus on the dual wavelengths UV lamps first (185 and 254 nm). You don’t need to go into detail on how photo oxidation works, just that it requires both wavelengths to work. You can then mention that 254nm wavelength lamps are good for antimicrobial purposes. UV energy catalyzes production of hydroxyl radicals (OH*). These hydroxyl radicals generate reactions which oxidize organic compounds. As the oxidation of organics progresses, reaction products become more polar (charged). These charged species are removed by a special ion exchange polishing cartridge

UV Technology (185 + 254 nm) Benefit Limitations
Conversion of traces of organic contaminants to charged species and ultimately CO2 ( ) Limited destruction of micro-organisms and viruses (254) Limited energy use Easy to operate Limitations Polishing technique only: may be overwhelmed if organic concentration in feed water is too high. Organics are converted, not removed. Limited effect on other contaminants. Good design required for optimum performance. Benefits are an efficient way to breakdown organics and sterilize water. The main limitations: Photo Oxidation – Can only be used as a polishing technique if TOC load is too high it will overload the lamp. Once organics are converted they must still be removed, so it can’t be the last purification step.

Contaminant Removal Efficiency
Inorganics Particulates Organics Bacteria Distillation Reverse Osmosis Ultrapure Ion Exchange Electrodeionization Ultraviolet light Carbon Ultrafiltration Microporous Filtration 2311BD10

Water Purification System Design Multi-Step Purification Process
RO systems RO + EDI systems Both Reverse Osmosis Remove up to 99% of feed water contaminants Progard Pack Pretreatment pack RO cartridge protection Elix Technology Electrodeionization Consistent production of high resistivity and low TOC water UV Lamp Production of water with low levels of Bacteria Pretreatment: The Progard™ TL pretreatment pack, the first step, removes: • Particles (0.5 µm filter) • Free chlorine and colloids (activated carbon filter) from tap water to protect the system. Additionally: • an anti-scaling agent protects the reverse osmosis membrane in hard water areas • bactericidal carbon prevents unwanted bacterial growth. Advanced Reverse Osmosis Reverse Osmosis (RO), the second step, removes % of ions and 99 % of all dissolved organics (MW >200 Dalton), micro-organisms and particles. Built-in advanced features provide 2 major benefits: • high water recovery: Part of the RO reject water is recycled back to the RO membrane feedwater stream. Water recovery can be adjusted up to 70 % to optimize water consumption, depending on the feedwater quality and the pretreatment sequence used. • constant product flow rate: Elix systems maintain a constant flow rate from 7-30 °C. Typically, standard RO-based systems suffer a decline in product flow rate of as much as 50 % as water temperature decreases. Elix Technology: Millipore’s patented Elix module, the third step, removes the remaining ions by electrodeionization. • Ion-exchange resins are continuously regenerated by the electric field applied within the module – eliminating the need to interrupt water production for hazardous chemical regeneration or costly resin replacement. • Resins are always of the highest quality: resins do not degrade as they are not exposed to harsh regeneration chemicals or moved outside the system. Ultraviolet Lamp: During the last step, the water is sanitized by a 254 nm UV lamp. This powerful UV lamp leads to a log reduction value (LRV) of 4 in the bacterial count of the water (a bacterial count of 10,000 cfu/ml will be reduced to 1 cfu/ml), irrespective of the system’s nominal flow rate. This allows the Elix system to produce optimum water quality for bacteria-sensitive applications. Product Water 1 2 3 4 Type II Tap water Type III Low Bacteria

Water Purification System Overview of Design Considerations

Major phases in a project
Definition of the needs Design of a total solution Budget estimation Tender (Bid) process Delivery of the units, accessories and consumables Installation Users training/Commissioning Additional phases Preventive maintenance Full support for validation

Design Process Key Steps
Dishwasher Direct Feed Ultrapure Polishing for HPLC General Glassware Rinsing 1 2 3 4 Define the pure water requirements and specifications Design the distribution loop Design the makeup system and storage tank Review and Finalize specifications and design pump UV sterile filtration monitoring Tap Water Pure Storage Explain four step. “Turn the process upside-down” or “design it backwards”

Design Process: Step 1 1 Defining the pure water requirements and specifications What purity level? How much water? When is it needed? Where is it needed? Dishwasher Direct Feed Ultrapure Polishing for HPLC General Glassware Rinsing

Defining the pure water requirements and specifications
1 Defining the pure water requirements and specifications What purity level? What labs and locations need purified water? What kind of work will be carried out in each lab, at each location? General rinsing/washing to sensitive trace analysis,…? Are there instruments that will need pure water? Glassware washers, steam sterilizers, autoclaves…..? Are there any “maximum” purity level requirements? What water quality is needed for each location? Ionic, Organic, and Microbiological Quality? Are there alert and action levels? Are there standard specifications to follow? How much water? When? Where? Dishwasher Direct Feed Ultrapure Polishing for HPLC General Glassware Rinsing

Definition of the needs Questions to select the right configuration and design
1 What purity level? How much water? When? Where? How much water is needed each day? In each lab, at each location,..? By the individual users, instruments, ultrapure polishing systems? How is the demand distributed during the day? Steady demand over the course of a day? Peak demands at certain times of the day? How many floors need water? Where is each location? Are there remote locations that need water? What are the distances between each location? Dishwasher Direct Feed Ultrapure Polishing for HPLC General Glassware Rinsing

1 Defining the pure water requirements and specifications
What purity level? How much water? When? Where? Additional questions: Does the equipment need to be validated? At all locations? Who will do the maintenance? Is a service/maintenance contact required? Are the water quality requirements similar between locations? How many researchers/scientists will work in each lab? Where can the equipment be located (space)? Where can piping be run? Are there plans for future expansion? Dishwasher Direct Feed Ultrapure Polishing for HPLC General Glassware Rinsing

Step 2: Designing the Distribution Loop
Define the distribution piping Design Layout Materials, welding method, valve type, pipe diameter Design Considerations Define Loop Purification and Monitoring Equipment Determine distribution pump performance Flow rate and pressure

2 Distribution Loop Layout Options: Gravity Feed
In the last few slides we reviewed the key design steps, some design tools and rules of thumb Millipore uses in designing a Total system for a lab facility. In addition to the design process of defining the equipment to meet user requirements it is important to also consider total system design approaches that that can help optimize and determine the design that will best meet the needs of the facility. The illustration above was in the past one of the more common approaches, one larger make-up system with storage and the distribution equipment located in a central location with purified water distributed throughout several labs or floors completing a distribution loop that returns back to the storage at the central location. This is only one approach and might not be the best approach. The needs of each floor, each department plus the specific water requirements of each lab and use point must be understood before considering how to supply purified water to the facility.

2 Distribution Loop Layout Options: Single Loop and make-up system Central Location In the last few slides we reviewed the key design steps, some design tools and rules of thumb Millipore uses in designing a Total system for a lab facility. In addition to the design process of defining the equipment to meet user requirements it is important to also consider total system design approaches that that can help optimize and determine the design that will best meet the needs of the facility. The illustration above was in the past one of the more common approaches, one larger make-up system with storage and the distribution equipment located in a central location with purified water distributed throughout several labs or floors completing a distribution loop that returns back to the storage at the central location. This is only one approach and might not be the best approach. The needs of each floor, each department plus the specific water requirements of each lab and use point must be understood before considering how to supply purified water to the facility.

2 Distribution Loop Layout Options: Single Loop and Duplex-central make-up system A variation of the first centrally located system is use of duplex make-up water purification systems providing purified water to the same storage reservoir and distribution. The duplex approach provides some redundancy at the primary make-up level reducing the risk of completely shutting down a facility. When one of these systems is down for routine maintenance or service the 2nd system is still providing purified water to the facility.

2 Distribution Loop Layout Options: Multiple Loop and make-up systems
Another approach is to break out the total system in parts, floor by floor or department by department, with each smaller system designed to meet specific requirements. For example: In the lower level of the illustration where the highest volume of water for the facility is required for dishwashers and washing. It may be a better approach to dedicate a system to this high demand instead of trying to build this into the complete distribution network. Other departments or floors can then be addressed with smaller systems designed specific to their needs.

2 Distribution Loop Layout Options: Multiple Loop and make-up systems and POU systems “Satellite” Units Yet another approach is to address specific needs using smaller point of use system that at a much smaller scale include the make-up purification system, storage and as needed additional polishing. In the illustration above this approach will avoid the need to extend piping to all departments potentially simplifying the main total water purification system and reducing cost.

Design Considerations; Avoid Dead legs
2 “6D rule” CFR212 regulations of 1976 Good Engineering practice requires minimizing the length of dead legs and there are many good instrument and valve designs available to do so. “6D rule” 0.59” Maximum dead leg = 6 times the pipe diameter 0.59” X 6 = 3.5” Maximum dead length of 3.5 inches Maximum length 6X pipe diameter (our example max is 3.5 inches)

Design Considerations; Avoid Dead legs
2 “2D rule” ASME Bioprocessing Equipment Guide of 1997 Good Engineering practice requires minimizing the length of dead legs and there are many good instrument and valve designs available to do so. “2D rule” 0.59” Maximum dead leg = 2 times the pipe diameter Example: 0.59” X 2 = 1.2” Maximum dead length of 1.2 inches

Design Considerations; Flow Velocity
2 Design system for 3 to 5 f/s (~1 to 1.5 m/s) to: Maintain turbulent flow Minimize biofilm on internal walls Balance between velocity and pressure drop Higher velocity results in too high a pressure drop Requiring a larger pump and risk of increased water temperature

Design Considerations; Flow Velocity
2 Velocity through distribution pipe: 3 to 5 ft/sec design target, (~1 to 1.5 m/s)

Define Loop Purification and Monitoring Equipment
2 Loop purification equipment to maintain water quality UV lamp Bacteria control TOC Reduction Filtration Membranes for Bacteria and particle control Ultra-filtration for Pyrogen removal Deionization – Ion removal Loop Water Purity Monitoring Resistivity TOC Bacteria Temperature Sanitant Monitors (Ozone)

Loop Monitoring 2 TOC Sanitary Sampling Valve Resistivity

Loop Bacteria Sampling
2 Sanitary Sampling Valve Designed for sanitary sampling (bacteria and endotoxin) Mid-stream sampling Zero-Dead leg when closed Sanitize easily in place Direct attachment to samplers

Determine the Distribution Pump Requirements
2 Pump selection is based on flow rate and pressure requirements Flow rate required defined in step 1 Pressure requirement Total Pressure requirement can be estimated by adding: piping pressure loss + loop equipment pressure loss pressure due to elevation changes pressure required at furthest point of use (25 psi typical) Select a pump that delivers the required flow rate and pressure Reduce pressure loss by increasing pipe diameter, (keeping balance with flow required and target velocity) For added reliability a duplex pumping system can be used

Distribution Systems Water Flow Dynamics; Pressure drop
2 Pressure drop through pipe: the resistance to water flow moving through a pipe (friction losses occurring along pipe walls and through fittings and valves) Key factors influencing pressure drop Pipe material, (surface roughness) Pipe diameter Pipe length Flow rate Determining pressure drop through pipe: Hazen-Williams formula for predicting pressure drop, (turbulent flow) Simplified: Hp = (L) x (Q)1.85/(d)4.86 Hp= pressure drop in psi L = pipe length in feet Q = flow in GPM d = pipe inside diameter (friction factor included for smooth surfaces)

2 Determining pressure drop through fittings: Fittings; (elbows, tees, unions, etc…..) Flow through fittings creates turbulence and adds to pressure drop “Equivalent pipe length” method most common Express each fitting as a length of pipe 90o elbow 2 feet 1 foot Example: 2 ft + 1 ft + (1) 90o elbow 90o elbow = 2 equivalent feet of pipe eq-ft = 5 feet total length

2 Determining pressure drop through additional loop equipment Refer to manufacturers specifications UV lamps: Typically 2 to 3 psi Filters and housings: Pressure loss data 20 inch Code-0 Durapore

2 Determine the Distribution Pump Requirements Example worksheet tool Helps track and automatically calculate all key parameters Sizing and selection of correct pump is a key step in the design process

2 Determine the Distribution Pump Requirements Pump performance curve 15 GPM and 180 feet of head (~78 psi) shown as an example Select the pump that meets the minimum requirements

Step 3 - Design the Makeup Purification System and Storage Tank
Select the make-up purification system to match the water quality required Size the makeup purification system to match the quantity required per day Size the storage tank to meet peak demands during the day Determine the pretreatment needed

Makeup System Sizing and Quality
3 Match to the quality requirement (defined in step 1) RO/EDI or RO/DI system for Type 2 pure water applications RO system for Type 3 more general applications Size the makeup system to match the quantity required per day (defined in step 1) Plans for future expansion? Are Duplex systems needed? Back-up for maintenance-down time. Option to add for future expansion

Sizing Makeup System and Tank
3 Sizing the makeup system is done in conjunction with the storage tank Sizing Examples: Company A needs water to clean vessels in the first two hours of the day shift. They need a total of 1200 Gallons in two hours. 1500 Gallon Tank with 100 gph make-up rate Company B needs pure water to feed automated Filling machine. They need 200 gallons per hour for an 8 hour shift. 200 Gallon Tank with 200 gph make-up rate

Determine the pretreatment needed for the makeup water system
3 Determine feed flow rate base on the make-up system water recovery rate Feed Flow Rate = RO Product / RO recovery rate Complete feed water analysis conductivity, chlorine, fouling index, pH, hardness, alkalinity…….. Select pretreatment options based on feed water analysis and manufacturers recommendations Multimedia Sand – Particulate contamination Carbon Filters – Chlorine and some organic removal Softeners – Hard water (Mg++ or Ca++ contamination) Cartridge Filters – Particulate and carbon options

4 Design Process Step 4 Step 4 - Finalize Design
Prepare Process Flow Diagram (PFD), supporting documents and specifications Design Controls and Monitoring Review Validation requirements Review who will maintain the equipment Consider service/maintenance plans Review requirements, specifications, design, equipment and PFD with customer/client Update and Finalize design as needed

Outline Questions ??? Contaminants in Water
Pure Water Applications and Quality Standards Water Purification Technologies Key Water Purification System Design Steps Systems Questions ???

Water Purification System for a Laboratory Facility Thank You!!
Millipore Corporation Bioscience Division Christopher Yarima Mike Kelly

Water Purification System for a Laboratory Facility

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