Today, energy and process plants are complex, closely networked systems. Operations managers in power plants, district heating networks, chemical plants, or in hydrogen and battery production must ensure that water of the required quality, quantity, and temperature is available. At the same time, requirements from standards such as VDI 2035, AGFW FW 510, and DIN EN 1717 are becoming increasingly stringent. For filling, topping up, or flushing, demineralized water (deionate) with conductivity values below 100 µS/cm and hardness values ≤ 0.3 °dH is often required. Disruptions in water treatment, for example due to the shutdown of in-house demineralization systems or during overhauls, can lead to costly production losses.
Mobile water treatment plants offer a solution here. They are modular, ready for operation within a few hours, and ensure the supply of compliant water to the plant even during unplanned events such as leaks, pump failures, or commissioning delays. ORBEN's trailer service delivers up to 120 m³/h of demineralized water, depending on the model. Thanks to reusable resin and intelligent logistics concepts, they achieve not only safety and flexibility but also sustainability and low total operating costs.
In the following article, we shed light on the most important questions surrounding mobile water treatment and trailer systems. We demonstrate how a 60 m³/h supply for a power plant overhaul can be implemented, what the differences are between container and trailer solutions, how long deployment takes, and how systems must be protected in winter. This information is aimed at asset and operations managers, as well as HVAC professionals and building services planners.
Planned overhauls are unavoidable for power plants and large-scale facilities. Turbines, boilers, or heat exchangers must be regularly inspected and maintained to ensure efficiency and safety. During these overhauls, a large amount of deionized water is often required, for example, to flush systems, conduct hot samples, or fill tanks. If the stationary water treatment system fails or is unavailable due to the overhaul itself, a short-term need arises. In the event of unplanned incidents such as defective ion exchangers, chemical malfunctions, or external quality issues, the risk is even greater: without an external supply, production losses, contractual penalties, and damage due to improperly filled systems are imminent.
Since 2009, ORBEN has offered a trailer service with a central base in Germany, specifically designed for overhauls and emergencies. The mobile units are modular in design and include various models (TR 10, TR 30, and TR 60) that can be used individually or in combination. By cascading multiple trailers, a total capacity of up to 120 m³/h can be achieved. Each trailer consists of an ion exchange system mounted on a semi-trailer, with optionally integrated pre-filters, reverse osmosis modules, and polishers. This design allows for quick connection to existing water lines.
A special feature of the ORBEN system is its scalable capacity: For an overhaul requiring high flow rates, two TR 60 units can be operated in parallel to deliver 120 m³/h. For smaller requirements, a TR 30 or TR 10 is sufficient, achieving conductivity values below 1 µS/cm. Additionally, a 24/7 emergency service with German-speaking support is available. This means a trailer can be delivered to your site at short notice, even on weekends or at night.
To rent a 60 m³/h trailer at short notice, please follow these steps:
Thanks to these structures, 60 m³/h of deionized water can be supplied even for major overhauls. The trailers replace the role of a permanently installed treatment plant and offer the possibility to continue production without interruption.
During the commissioning of new or modernized plants, large quantities of demineralized water are often required. Conductivity, hardness, and pH value must comply with standards to prevent corrosion, scaling, and deposits. For example, VDI 2035 stipulates that for hot water heating systems, the filling and make‑up water should have a conductivity below 100 µS/cm; hardness ≤ 0.3° dH is a prerequisite. AGFW FW 510 and DIN EN 1717 also specify clear limit values for district heating systems and drinking water hygiene.
In the event of a water shortage or insufficient flow during commissioning, delays and damage are imminent: pumps cannot be vented, hot runs are postponed, and the entire start‑up is delayed. In the worst case, systems must be filled with substandard water and later flushed at high cost.
Mobile trailer systems offer a solution to avoid bottlenecks during commissioning. They can be operated in parallel with existing stations to cover short‑term peaks. Thanks to their modular structure and flexible scalability, 60 m³/h or more of deionized water can be supplied. The trailers usually contain mixed‑bed ion exchangers with a pH‑controlled regeneration process, ensuring that the produced water meets standard requirements.
For long‑term safeguards, the trailer can be combined with additional components such as reverse osmosis (RO) or electrodeionization (EDI) to reduce the load on the ion exchangers and extend resin lifespan. This concept reduces operating costs, as the resins need to be regenerated less frequently (total operating cost optimization). Through reusable resin and the recirculation of exhausted water, resources are conserved and the ecological footprint is improved.
International examples show how mobile systems support large projects. An article from the trade magazine “Maintenance and Engineering” reports on a power plant start‑up where an additional 100 m³/h of demineralized water was required. Mobile filters, reverse osmosis, and ion exchange units enabled rapid start‑up supply, ensuring the schedule was met. Another project in a chemical park in Germany required 200–250 m³/h of demineralized water during a three‑month overhaul; mobile units provided this quantity and kept production running.
Experience shows that mobile systems are useful not only in emergencies but also as a strategic addition for commissioning. They help to adhere to schedules, avoid penalties, and protect investments. In combination with detailed documentation, auditability is guaranteed, which is essential in industries with high regulatory requirements (e.g., pharma, energy, hydrogen production).
Mobile water treatment plants are offered in various form factors. The most common variants are container‑based systems (20‑ or 40‑foot containers) and trailer‑based systems (semi‑trailers with swap bodies). When deciding on a variant, both technical and logistical criteria play a role:
The decision between a container and a trailer also depends on the total costs. Trailers have higher daily rental costs, but due to their high capacity, they offer lower total operating costs per m³ of deionized water produced. They reduce the effort for multiple transports or the setup of several smaller systems. Container systems are more affordable but can quickly reach their limits with higher demand. A modular combination (e.g., two containers plus mobile ion exchangers) is possible, but it increases coordination effort.
Saur emphasizes that mobile systems allow production to continue during maintenance, thus avoiding financial losses. Additionally, extra units can be added or removed as needed to scale the flow rate. It is important to consider the total costs: in addition to rental costs, logistics, connections, electricity and chemical consumption, regeneration cycles, and the risk of failure must be factored in.
The following checklist helps in choosing between a container and a trailer:
The decision should be made in close consultation with the provider, who will consider local conditions and regulatory requirements. This ensures a tailored solution that is technically, economically, and logistically optimal.
The provision of a mobile trailer system depends on several factors:
For planned revisions the following lead times are recommended:
In emergencies delivery can be significantly faster. Since the trailer is mounted on a semi-trailer, it can be loaded and transported to the customer within a few hours. ORBEN emphasizes that the trailers have also been available for emergencies since 2009 and cover short-term projects. Realistically, this is 6–36 hours, depending on distance, availability, and any border formalities. For critical infrastructures, it is advisable to agree on a framework contract or an "Emergency Preparedness Plan" to secure capacities.
On-site setup is relatively quick. The trailers are equipped with standardized connections. The operator only needs to provide fresh water and wastewater lines, as well as electricity (often 400 V, 32–63 A). For commissioning, measuring devices for monitoring flow and conductivity are connected. After that, the system operates autonomously.
During operation, the ion exchanger is regenerated or replaced at regular intervals. For multi-use resin systems, resin transport is handled by a logistics service ("Resin Express") and regeneration takes place at the Orben plant, ensuring high availability. After use, the trailer is disconnected by the operator and picked up. Dismantling usually takes less than two hours.
Most water treatment plants are designed for year-round operation. Nevertheless, frost and cold can cause serious damage. A publication by Whipps points out that freezing pipes and components can lead to cracks, leaks, and downtime. In mobile systems, external pipes, valves, and ion exchanger vessels are particularly exposed. Cold temperatures also increase water viscosity and slow down chemical reactions and ion exchange processes, as outlined in a guide by Everfilt. This reduces system performance, and water quality can suffer.
To ensure the trailer service operates reliably in winter, the following measures should be implemented:
With these measures, a continuous supply of deionized water can be ensured even in winter. ORBEN offers consultation on frost protection and emergency equipment (heating mats, insulated tarpaulins) if required.
Sustainability is becoming increasingly important for plant operators. Ion exchange resins have a limited lifespan but can be regenerated multiple times. The concept of reusable resin, which has been established in Germany for years, drastically reduces resource consumption and waste. After exhaustion, the resin is regenerated in a central facility and reused. The article "Ion Exchange Resin: Selection, Lifespan & Regeneration" emphasizes that standards like VDI 2035 require conductivity < 100 µS/cm and hardness ≤ 0.3° dH, which is why the quality of resin regeneration is crucial. High-quality regeneration leads to fewer regeneration cycles, saves chemicals, and lowers total operating costs.
When purchasing or renting water treatment systems, one should consider not only investment costs but also the total costs over the lifespan (Total Cost of Ownership). These include:
An integrated cost-benefit analysis reveals that mobile trailers are often the most economical solution despite higher rental prices. Furthermore, they contribute to a better environmental footprint when regenerative technologies and reusable resin are used.
Operational reliability is crucial for operators of district heating networks and power plants. They must comply with strict requirements from VDI 2035 and AGFW FW 510. Articles on the ORBEN website emphasize that compliance with standards provides legal and insurance protection. In the event of temporary failures of stationary systems, a trailer can ensure the supply of heating water. It is connected as a parallel line, reduces conductivity values, and protects boilers and pipelines from corrosion. Another application is closing gaps in network expansions: If a new district heating pipeline is integrated into an existing network, large quantities of water must be replenished. Trailers ensure quality during the construction phase.
The chemical industry uses ultrapure water with extremely low conductivities (< 1 µS/cm). Production must not be interrupted during planned plant modifications or piping work. Mobile reverse osmosis and ion exchange modules, as installed in ORBEN trailers, can deliver 200 – 250 m³/h. Thanks to remote monitoring, the conductivity value is continuously monitored, and in case of deviations, it automatically switches to backup systems. This flexible provision is particularly important for transitional phases before a new central water treatment plant becomes operational.
Ultrapure water (partially ASTM Type II or III) is required for forward-looking industries such as hydrogen electrolysis or battery manufacturing. The plants are often under construction, and the infrastructure is being gradually expanded. Mobile systems bridge the gap until the permanent plants are completed. They deliver consistent quality while processes are still being scaled. Furthermore, they serve as a backup solution for peak loads when the stationary plant reaches its limits.
In addition to overhauls and start-ups, mobile trailers are also suitable for emergencies: pipe bursts, floods, fires, or chemical contaminations can render water treatment inoperable. The rapid deployment of a trailer can limit the damage. According to Saur, mobile units can be brought to the site within a few hours. Thanks to their modular design, necessary functions (filtration, softening, desalination) can be flexibly combined, allowing for a quick and needs-based supply in a crisis.
VDI Guideline 2035 is considered a recognized technical standard for hot water heating systems up to 100 °C. It requires that filling and make-up water be predominantly demineralized and that limit values for conductivity, hardness, pH value, and oxygen are observed. In particular, it is recommended to keep the conductivity below 100 µS/cm. For large systems, the total amount of salts is also limited to prevent corrosion. Mobile trailer systems can meet these requirements and document operation so that the plant operator can provide proof during an inspection.
The German Association for District Heating (AGFW) sets limit values for district heating water with Guideline FW 510. Here, the pH range, oxygen content, and electrical conductivity are regulated to ensure the longevity of pipes and heat exchangers. The requirements are sometimes stricter than in VDI 2035, as district heating networks usually have higher pressures and temperatures. Mobile systems must therefore be able to reduce conductivity to < 50 µS/cm in some cases. This is possible through the use of mixed-bed ion exchangers and polishers in the trailers. Seamless documentation of quality fluctuations is crucial to prove compliance with standards to network operators and authorities.
For applications in the drinking water sector (e.g., filling water in hot water systems), the European standard DIN EN 1717 also applies. It regulates the protection of drinking water from contamination due to backflow. Therefore, a suitable system disconnector must be installed in mobile systems. ORBEN trailers are equipped with integrated system disconnectors and backflow preventers to meet the requirements. This eliminates the need for retrofitting for operators.
Both VDI 2035 and AGFW FW 510 recommend continuous monitoring of feed and operating water. Parameters such as conductivity, pH value, temperature, and flow rate must be recorded. ORBEN's mobile trailers are equipped with sensors and data loggers that capture these values. Via a remote connection, this data can be provided to the operator or auditor. Auditability is particularly important in industries with ISO 9001 or ISO 14001 certification.
To determine whether mobile water treatment is suitable for your project, you should analyze the following factors:
This systematic evaluation allows for sound decisions to be made. Consultation with experienced service providers like ORBEN helps to correctly weigh the parameters.
Mobile water treatment and trailer systems are an essential building block for the safety and flexibility of modern energy and process plants. They enable asset and operations managers to handle overhauls, commissioning, and emergencies without compromising water quality. ORBEN's trailers, with their TR 10, TR 30, and TR 60 models, offer flow rates of up to 120 m³/h, can be combined modularly, and have been successfully used since 2009 for overhauls, start-ups, and long-term operations. Through reusable resin and a professional logistics concept, total operating costs and ecological impacts can be minimized.
The use of mobile systems should always be considered in conjunction with the relevant standards (VDI 2035, AGFW FW 510, DIN EN 1717). Careful planning, consideration of lead times and frost protection measures, as well as a well-founded decision between container and trailer solutions, are prerequisites for successful projects. As practical examples show, mobile systems can provide short-term capacities, thereby adhering to schedules, preventing production downtimes, and increasing operational reliability.
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