A demineralisation plant preventive maintenance schedule lists the checks and jobs done on the equipment at fixed intervals, how long each takes, and in what order of frequency, so problems are found before the demineralisation plant fails. This page gives the schedule used in the PlantOps360 task library for demineralisation plant (plant / ion exchange), which follows common industry practice for general-purpose equipment. It is also searched for as DM plant, ion exchange, mixed bed, cation anion.
The maker’s manual and your site safety procedures always come first where they differ. Intervals set by law differ by state.
Demineralisation plant preventive maintenance schedule and checklist
| How often | Task | Estimated time |
|---|---|---|
| Daily | Record conductivity, silica and service flow; log regeneration cycles | 10 min |
| Weekly | Check regeneration chemical tank levels (acid and alkali) and dosing equipment | 15 min |
| Monthly | Check valves, strainers and pumps; check resin bed levels and for resin carry-over | 30 min |
| Quarterly | Check conductivity meters and sampling lines; inspect distribution nozzles through the inspection port | 60 min |
| Half-yearly | Check resin condition: capacity test or resin sample analysis | 120 min |
| Annual | Inspect internals and rubber lining; top up or replace resin as needed; service valves and instruments | 480 min |
Demineralisation plant maintenance frequency and yearly workload
At the estimated times, one demineralisation plant needs about 96 hours of preventive maintenance a year. The biggest single job is “Inspect internals and rubber lining; top up or replace resin as needed; service valves and instruments” at 480 minutes, done annual. Multiply by the number of units you have to see the workload for your plant.
| Frequency | Tasks | Time per round | Hours per year |
|---|---|---|---|
| Daily | 1 | 10 min | 60.8 h |
| Weekly | 1 | 15 min | 13.0 h |
| Monthly | 1 | 30 min | 6.0 h |
| Quarterly | 1 | 60 min | 4.0 h |
| Half-yearly | 1 | 120 min | 4.0 h |
| Annual | 1 | 480 min | 8.0 h |
What goes wrong on a demineralisation plant without preventive maintenance
- Resin exhaustion or fouling
- Regeneration chemical dosing faults
- Valve and strainer failures
- Conductivity and silica breakthrough
What to watch between services
- Outlet conductivity and silica
- Service flow and run length
- Acid and alkali tank levels
Safety and statutory notes for demineralisation plant maintenance
Acid and alkali are corrosive. Use the right PPE, and keep the eyewash and safety shower working and tested.
Where a demineralisation plant preventive maintenance schedule is used
This equipment is used in the industries below. Each link opens the preventive maintenance schedule guide for that industry, and the maintenance software page where we have one.
- Preventive maintenance schedule for electronics manufacturing plants · maintenance software for electronics
- Preventive maintenance schedule for pharmaceutical plants · maintenance software for pharmaceutical · maintenance software for api bulk drugs
- Preventive maintenance schedule for chemical, fertiliser and petrochemical plants · maintenance software for chemical
- Preventive maintenance schedule for food, dairy and beverage plants · maintenance software for food processing · maintenance software for dairy
- Preventive maintenance schedule for agro, grain, edible oil and sugar plants · maintenance software for sugar and distilleries
- Preventive maintenance schedule for packaging, paper and printing plants · maintenance software for packaging · maintenance software for paper and pulp
- Preventive maintenance schedule for textile and garment mills · maintenance software for textile
- Preventive maintenance schedule for steel, foundry, forging and metal plants · maintenance software for steel and metals
- Preventive maintenance schedule for cement, glass, ceramics and building materials plants · maintenance software for cement
- Preventive maintenance schedule for oil, gas and refinery facilities · maintenance software for oil and gas
- Preventive maintenance schedule for thermal and hydro power plants · maintenance software for power plants
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Browse the full list of equipment preventive maintenance schedules (317 types).
Run this demineralisation plant schedule in maintenance software
In preventive maintenance software, each row above becomes a recurring task on the asset with its checklist, time estimate and parts. Tasks can be triggered by calendar date, running hours, meter readings or production cycles, each completed task is recorded with the person and date, and a failed check can open a work order. For the method behind it, read the guide to the preventive maintenance schedule, or use the free generator to get a 12-month plan for your whole equipment list.
Build my preventive maintenance schedule (free Excel)
Frequently asked questions
How often should a demineralisation plant be serviced?
In our schedule a demineralisation plant has 6 tasks: 1 daily, 1 weekly, 1 monthly, 1 quarterly, 1 half-yearly, 1 annual. The biggest job is “Inspect internals and rubber lining; top up or replace resin as needed; service valves and instruments”, which is done annual. Always follow the maker’s manual where it gives a different interval.
What is included in demineralisation plant preventive maintenance?
It covers routine checks and jobs such as “Record conductivity, silica and service flow; log regeneration cycles”, “Check regeneration chemical tank levels (acid and alkali) and dosing equipment”, “Check valves, strainers and pumps; check resin bed levels and for resin carry-over”, up to the annual overhaul or inspection. The full list with times is in the table above.
How many hours of maintenance does a demineralisation plant need per year?
About 96 hours per unit per year at the estimated times in our library, including the daily checks done every day. Use it to plan workload, not as a benchmark.
Is there a free demineralisation plant maintenance checklist?
Yes. The table on this page is a ready checklist. The free preventive maintenance schedule generator turns it into a 12-month Excel schedule for your list of equipment, with monthly workload hours.