ROPV R80 E Series User Manual
Contents
1. 01 10 707 7000 5961 1008 22 44 187151 009 Th Sao We AA August 2005C ROPV R80 E Series Manual _1200 2089088 rl nt el el 1110773 1008 808 2 n l M 2 1 013430 0 NIGYVH E itt 11 EE MEH m CC a o TO Y rann Me reddy 5 1 3391 91 100 31155914 i OL 1541105 01 10179 1951 091950 T 1 40 LIM I DEP aay 0 06 Sai 01 08 i p a 1 August 2005C sa amg Mpt 1194 44 1 VIDL OF E202 900082. gt ROPY HARBIN ROPV INDUSTRY DEVELOPMENT CENTER ROPV R80 E Series User Manual For Use with the Following ROPV Pressure Vessel Models R80 600E R80 800E R801000E R80 1200 Headquarters Harbin ROPV Industry Development Center 100 Hongqi St Xiangfang District Harbin China 150036 Tel 86 451 5515 5144 Fax 86 451 5515 5124 Email ropv ropv com cn Website www ropv com cn ROPV R80 E Series Manual August 2005C General Product Description R80 E Series End Port Membrane Housing R80 600E Design Pressure R80 800E Design Pressure R80 1000E Design Pressure R80 1200E Design Pressure Min Operating Temp Max Operating Temp Factory Test Pressure Burst Pressure Operating pH Range Cleaning pH Range at 120 F 49 C at 120 F 49 C at 120 F 49 C at 120 F 49 C 600 PSI 4 1Mpa 41 Bar 800 PSI 5 6Mpa 56 Bar 1000PSI 6 9 69 Bar 1200PSI 8 83 Bar 20 F 6 C 120 F 49 C ASME 1 1x Design Pressure Standard 1 5x Design Pressure 6X Design Pressure 3 11 2 12 less than 30 minutes General Warning High Pressure Membrane Housing ROPV Pressure Vessels are designed to provide safe operation over a long service life if properly installed operated and maintained The vessel may cause loss of life severe bodily harm or property damage if not correctly installed operated or maintained Read and understand all guidelin
3. Mount vessel using strap saddle hardware provided and span recommended the engineering drawing e Do not over tighten the straps vessel must be allowed to expand under operation e Maximize the connection flexibility to allow for vessel growth under pressure Align the end ports with the system manifold correcting any misalignment before final installation e Provide overpressure protection in the system safety devices e Inspect end closures regularly for signs of corrosion Immediate corrective action and or replacement is suggested in case of corrosion e Relieve system pressure before working on the vessel Do not attempt to over tighten the Permeate Port connections as this may damage the end closure One turn past hand tight should be sufficient Ensure that the Trust Cone is installed on the downstream end of the vessel e Never operate the vessel in excess of its ratings This may void the warranty and cause bodily or property damage e Do not operate the vessel permeate port over 125PSI e Flush the vessel with permeate before system shutdown to reduce the chance of corrosion Do not install the vessel in direct sunlight e Operate the vessel within the recommended pH range Operating Range 11 Cleaning pH Range 2 12 less than 30 minutes ROPV R80 E Series Manual August 2005C Head Removal Step 1 Shut Down System and Relieve System Pressure The system must be shut down and all pressure rel
4. additional information about cleaning head components Scratched or damaged components should be replaced with ROPV supplied replacement components All o rings should be carefully inspected for signs of damage It is recommended that all o rings be replaced during each complete servicing of the vessel Failure to do so may Cause poor system performance Step 2 Install Feed Concentrate O rings All o rings should be coated with a thin layer of glycerine before installation Care should be taken to minimize the amount of glycecrine and any excess should be removed One o ring should be placed into each of the two grooves located on the inside diameter of the feed concentrate port hole in the sealing plate Make sure o rings are completely seated in the grooves Step 3 Install Permeate Port O rings One o ring should be placed at the base of the threaded side of the port at the larger diameter section of the port that seats against the sealing plate One o ring should be placed in each of the two grooves on the inside diameter of the permeate port side that is not threaded ROPV R80 E Series Manual August 2005C Step 4 Assemble Sealing plate and Permeate Port Push the sealing plate down onto the permeate port with the sealing plate o ring toward the top or threaded end of the permeate port It may be necessary to use your body weight to seat the sealing plate Step 5 Assemble Feed Concentrate Port Place the feed concentrat
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7. Follow All Steps Outlined in the Head Reassembly Section Step 2 Install Head Hold the head assembly with both hands square to the axis of the vessel Push firmly with both hands until the head is correctly positioned and the retaining groove is visible It may be necessary to use a rubber mallet to tap the head into its engaged position The thrust cone must be installed with the head at the downstream end of the vessel Step 3 Install Locking Kit Segments Clean and dry the retaining groove Position the first two locking segments No 1 and No 2 in picture so that the end section sits in the retaining groove Position the third locking segment No 3 into the last area Position the securing ring as shown and use 6 7 32 hex wrench to tighten the screw until snug Do not over tighten maximum torque guideline 10Nm Install the two other segments in the same manner Conduct a final tightness check of each screw after all three segments are installed Step 4 Reconnect Permeate Piping Reconnect the system permeate piping to the permeate port Step 5 Pressurize System A thorough pre pressurization inspection should be conducted including verifying that the heads are properly installed system piping connections are in place elements are installed adapters are installed and thrust cone is installed at downstream end of the vessel ROPV R80 E Series Manual August 2005C Step 6 Inspect for Leaks All connecti
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9. and slowly pull from the bearing plate permeate port A slight rotating motion may ease the removal of the adapter There is a set of double o rings on the inside diameter of the permeate port that must be inspected for damage once the adapter is removed Damaged o rings must be replaced before re installation Step 3 Remove Bearing Plate Use a wrench to remove the permeate port Locknut The locknut is reveres threaded or left hand threaded and must be turned clockwise to be removed and counter clockwise to be installed After removing the locknut the bearing plate and sealing plate can be separated ROPV R80 E Series Manual August 2005C Step 4 Remove the Permeate Port Grasping the sealing plate rock the permeate port slightly and pull away from sealing plate It may be necessary to tap the permeate port on the smaller end with a rubber mallet to release the seal bond Once it is removed check the sealing plate o ring seated between the permeate port and the sealing plate Inspect for damage or foreign matter Replacement o rings are recommended during all head rebuilds Step 5 Remove the Feed Concentrate Port Remove the two pieces of feed concentrate port fixture Grasping the sealing plate rock the feed concentrate port slightly and pull away from sealing plate It may be necessary to tap the feed concentrate port on the smaller end with a rubber mallet to release the seal bond Step 6 Clean All Components All co
10. e port in the sealing plate opening and secure using the two feed concentrate port fixtures Step 6 Assemble the Bearing Plate Position the bearing plate over the sealing plate pushing them together so that the threaded portion of the permeate port is visible Step 7 Thread Lock Nut Onto Permeate Port Lock nut should be tightened to hand tightness using a wrench for the final half turn Do not over tighten the Lock Nut maximum torque guideline 15Nm Note that the threads of the Permeate Port are reverse or left hand threaded 2 ROPV R80 E Series Manual August 2005C Step 8 Install Adapter O rings All o rings should be coated with a thin layer of glycerine before installation Care should be used to minimize the amount or glycerine applied and any excess should be removed Seat one permeate port o ring into each of the two grooves located at the element end outside diameter of the adapter Step 9 Install Adapter The adapter should be pushed into the permeate port until the wider diameter middle section is flush against the end of the permeate port Simultaneously pushing and turning the adapter will ease installation Step 10 Install Head O ring All o rings should be coated with a thin layer of glycerine before installation Seat the head o ring into the groove on the outside diameter of the head Complete Head Assembly with Adapter ROPV R80 E Series Manual August 2005C Head Installation Step 1
11. e proven an effective and easy way to remove the vessel head without causing any damage to the vessel ROPV R80 E Series Manual August 2005C icture 3 Picture 1 Detail picture of head removal tools Picture 2 Thread the center piece into the permeate port of the head assembly to hand tight Do not over tighten the center piece Picture 3 Position nut bearing rod and bearing block as shown Turn bearing rod clockwise The head will move with the bearing rod as it moves toward the end of the vessel You will be able to remove the head once it has cleared the retaining groove area of the vessel Alternative Head Removal It is possible to remove the head assembly without the ROPV head removal tools The feed concentrate can be used as a handle to pull the head from the vessel A strong tug lay be required to break the head seal bond but do not use excess force on the feed concentrate port A slight rocking motion will help break the seal bond Complete Head Assembly with Adapter ROPV R80 E Series Manual August 2005C Head Disassembly and Inspection Step 1 Remove the Head O ring Use a non metallic rounded tool to start the o ring out of the o ring groove Once a small portion of the o ring has been lifted out of the groove use your hand to work the remainder of the o ring out of the groove Damaged or cut o rings must be replaced during re installation of the head Step 2 Remove Adapter Grasp the adapter
12. es provided in the vessel User Manual Observe every precaution contained therein Failure to do so may result in malfunction and potential catastrophic failure It is recommended that only qualified technicians experienced in servicing hydraulic systems work with this vessel Misuse incorrect assembly or use of damaged corroded components may result in catastrophic failure Vessel Use and Precautions Positive pressure up to the design pressure PSI of the specific model being used e Accommodates standard 8 nominal diameter spiral wound element e The required vessel element interface hardware is supplied with the vessel Ensure that an element adapter is installed at each end of the vessel before use e Vessel expands under pressure and careful consideration must be taken when installing straps saddles and system connection piping e Installation with the straps saddles provided is strongly recommended e Vessel should not support any other system components Connections should be non load bearing e Periodic inspection of the vessel end closure is recommended to ensure all parts are dry and free of corrosion e Failure to understand and follow all precautions may void warranty and result in catastrophic failure of the vessel ROPV R80 E Series Manual August 2005C These guidelines are subject to change Please check with to ensure that the User Manual is the latest version for the vessel model being used
13. ieved before conducting any maintenance or repair on the vessel Step 2 Disconnect Permeate Piping The system permeate piping must be carefully removed from the permeate port of the vessel Step 3 Inspect End Closure The end closure should be inspected for any signs of corrosion or damage Surface corrosion can be removed with a wire brush while flushing with water Damaged components should be replaced with approved components from ROPV Step 4 Disconnect Locking Screws Each of the three locking segments is held place with a securing ring The securing ring is held in place with 3 locking screws The locking screws be unthreaded using an M6 7 32 hex wrench The locking screws should be unthreaded from the head only not from the locking segment The locking screw and locking segment can be removed together Step 5 Remove the Locking Segment Screw Assemblies The locking segment screw assemblies should be easily removed from the retaining groove Should the assemblies be difficult to remove it may be necessary to rock the head slightly or tap the head inward with a rubber mallet Be careful when using metal tools avoiding leveraging against the sidewall of the vessel or scratching the inside surface of the bell area Step 6 Remove the Head Assembly with One of the Following Techniques ROPV Head Removal Tools A set of head removal tools is available from ROPV While not necessary for head removal they hav
14. mponents should be cleaned with mild soap solution or clean water The components should be air dried or dried with a lint free towel Step 7 Inspect All Components All components should be carefully inspected for signs of corrosion and damage Components exhibiting such should be replaced before re installation All o rings should be carefully inspected for signs of damage It is recommended that all o rings be replaced during each complete servicing of the vessel Failure to do may cause poor system performance Step 8 Inspect Inside Vessel Surface The inside surface of the vessel should also be inspected once the membrane elements have been removed Special attention should be paid to identify any scratches damage or foreign matter Surface scratches can be repaired by carefully sanding the effected surface with 600 grit sandpaper A combination of soapy water and fresh water should be used to flush the area during sanding Clean water should be used to clean the area after sanding Any extemporaneous matter can be removed with a soft cloth soapy water and a clean water flush Damaged vessels should not be used under any circumstances ROPV R80 E Series Manual August 2005C Picture of Disassembled Head Components ROPV R80 E Series Manual August 2005C Head Reassembly Step 1 Inspect All Head Components All head components should be free from scratches foreign matter or any sign of damage Please see Step 6 above for
15. onduct a field repair of the Product 3 issue a credit for the original cost of the Products This is not a statement of limitations for warranty performance and ROPV reserves the right to conduct warranty performance outside of the items shown Products returned to ROPV for inspection or testing must be shipped freight prepaid at the Customer s expense If a breach of warranty is confirmed ROPV will bear all costs related to the inspection and testing If the Product failure is found to be caused by cause other than breach of warranty all costs related to the inspection and testing of the Product will be borne by the Customer This includes a USD 500 per day fee and all related travel expenses All reported defects must be submitted to ROPV in writing Disclaimer ROPV makes no expressed or implied warranty other than that specifically set forth in this warranty statement ROPV disclaims any warranty of merchantability or of fitness for a particular purpose ROPV s liability under the terms of this warranty shall not exceed the purchase price of the Product which are claimed to be defective ROPV shall not be liable for any consequential or incidental damages whatsoever including but not limited to injuries or damages to person or property loss of business profits business interruption loss of use cost of removing installing Products or the claims of third parties Warranties or Representations by Others No agent employee dealer or o
16. ons should be free from leaks Do not operate leaking vessels Piping and Mounting Recommendations U bend pipe with two flexible Victaulic connections or flexible hose at each end Do not force any connections The Header and related piping should be self supported Space strap saddle locations using 5 dimension shown in model engineering drawing 4 and longer vessels a third strap saddle assembly to be installed at the center point of the vessel Tighten straps to hand tightness plus one turn Manifold span should be greater than vessel span to allow for vessel growth under pressure ROPV R80 E Series Manual August 2005C R80 E Series Parts List Locknut Fixture Screw Inside O rino Permeate Port Port O ring ROPV R80 E Series Manual August 2005C ROPV Limited Warranty Harbin Industry Development Center hereinafter called ROPV vessels the Product are warranted to the original purchaser the Customer under normal use and if installed operated and maintained in accordance with applicable User Guides to be free of defects in material and or workmanship for a period of one 1 year from date of manufacture subject to the following Any replacement Product or Part will be warranted only for the remainder of the original warranty period or thirty 80 days whichever is longer Exclusions from this Limited Warranty The warranty shall be void if 1 defects are not
17. reported during the warranty period 2 the Product is subject to accident damage incorrect installation mishandling abuse misuse negligence or accident by any other party 3 problems caused by modification or alteration 4 chemical exposure or acts of nature 5 any item manufactured by other companies 6 wear on replaceable components under normal conditions seals are excluded from this warranty Procedure for Obtaining Warranty Performance ROPV reserves the right to determine if a reported defect is a breach of this warranty This may require at discretion one or more of the following 1 an inspection or test of the Product and or the system in which it was installed by an ROPV representative the customer is responsible for arranging access to the Product 2 an inspection or test of the product and or the system in which it was installed by the Customer 3 an inspection or test of the product and or the system in which it was installed by third party inspector appointed by 4 return of the Product to ROPV s factory for inspection or testing This is not a statement of limitations for warranty performance and ROPV reserves the right to conduct warranty performance outside of the items shown If the Product is found by ROPV to be defective under the terms of this warranty ROPV will perform one of the following at its option 1 supply a substantially similar replacement part based on FOB factory terms 2 c
18. ther person has any authority to make any warranties or representations concerning ROPV or the Product ROPV is not responsible for such claims of warranty or representation ROPV R80 E Series Manual August 2005C 1 0 4094 l ties i it 1009 409 1 C asg maea 9 aw ep r ees epee eaten o TEI b 1 L i i t radi ae inst RET ira ptr meds me 5 1 __ 0 A EE TOLLON LOOKIN 01 1081687 59 21000 2009 20125 ata trott Teas T SEM TOIN 1 1100 329319231 Wd JIT T 5 3017708 40 113 1
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