8 Inch Side Port FRP Pressure Vessel User Manual
Contents
1. 8 Inch Side Port FRP Pressure Vessel User Manual 11 ROPI 4 3 Head Disassembling Read this article carefully before disassembling the head assembly to prevent damaging its components 4 3 6 Inspection Make sure that the end cap is removed from the vessel according to lt Opening the Vessel gt 4 3 7 Remove the adaptor and seals Hold the bearing plate tightly with one hand and pull the adaptor out of the permeate port with the other hand remove the adaptor seals and the sealing plate seals 4 3 8 Remove the permeate port locknut Remove the locknut using a dedicated wrench The locknut is left hand threaded and must be turned clockwise to be removed Figure 2 7 Remove the locknut Figure 2 8 Remove sealing plate 4 3 9 Separate the bearing plate and sealing plate Pull the sealing plate with one hand to separate it from the bearing plate 4 3 10 For parted seal plates pull the permeate port out of the sealing plate and remove the permeate port seals and the seals inside the sealing plate Figure 2 9 8 Inch Side Port FRP Pressure Vessel User Manual WWW ropv com cn 12 ROPI 4 3 11 Remove the permeate port seals 2 10 Remove seals Carefully remove the seals to prevent damage to the sealing surfaces It is recommended to replace all used seals with brand new seals Figure 2 11 Head breakdown figure 1 sealing plate Components sealing plate adaptor bearing plate per2. o E mail service ropv com cn Website WwWw ropv com cn 8 Inch Side Port FRP Pressure Vessel User Manual WWW FrOpV com cn 33 ROPI Appendix I Pre Running Check List ame ating resurerating Wawel Membrane is loaded as per requirements YESo NOg Membrane ope Adaptor is installed as per requirements YESo NOo elements Thrust ring is installed as per requirements YESo NOo All components are clean and in good conditions YESo NOo Vessel is installed and fixed as per requirements YESo NOo Vessel Head is assembled as per requirements YESo NOo Locking kit segment and securing ring high YESo NOo pressure vessels are installed as per requirements The pressure gage of closed vessel reads the same as YESO NOG that of the system Pipes are connected as per requirements without YESO NOG ee stress concentration Piping connections All piping components are in good conditions YESo NOo Installation staff Installation date Inspector Inspection date 8 Inch Side Port FRP Pressure Vessel User Manual 34 Appendix II Maintenance Check List Name Pressure rating Times of Running time l maintenance Item Status Treatment Corrosion YESo NOog Deterioration YESo NOo Damage YESo NOo Leakage YESo NOo Inspector Inspection date Maintenance staff Maintenance date 8 Inch Side Port FRP Pressure Vessel User Manual WWW ropv com cn 35 ROPI ROPV
3. 8 Inch Side Port FRP Pressure Vessel User Manual 14 ROPI 4 5 Cleaning and Inspection of the non metallic components Non metallic components include sealing plate permeate port adaptor permeate port locknut permeate port plug and all seals 4 5 1 Inspect components for scale corrosion or salt deposit Place the components into a bucket filled with mild soap solution and clean them to remove the deposits 4 5 2 Flush all components with clean water 4 5 3 Dry the components with compressed air or a clean and dry towel 4 5 4 Inspect all components carefully for any structural defects or damage in the seals For example cracks in the permeate port or the locknut damage in the threads aged deformed or damaged seals Replace any damaged or defective component with new ones 4 5 5 Replace all components that need to be changed upon inspection 4 5 6 Inspect carefully the Feed Concentrate ports and attachments to the shell to ensure that connections and seals are structurally sound Please contact ROPV for any questions Please do not conduct any repair work before consulting with the manufacturer for guidance except for replacing head components lf chemical reaction problems occur like cracks or discoloration on the vessel or its components please contact please contact ROPV at service ropv com cn 4 6 Head Assembly Read and follow this section Incorrect assembly may result in catastrophic head failure
4. 4 6 1 Lubricate and install the seals We recommend using brand new seals for head assembly Lubricate seals using glycerin or silicone base lubricant NO LNSLLV 4 6 1 1 Lubricate the permeate port seals and place them in the grooves 8 Inch Side Port FRP Pressure Vessel User Manual 15 Figure 2 13 Install the permeate port seals 4 6 1 2 Head with parted sealing plate Lubricate the sealing plate seal and place it in the groove located on the inside diameter of the sealing plate Lubricate the permeate port seals and place them in the grooves located on the inside diameter of the permeate port Lubricate the permeate port seals and place it onto the outer edge of the permeate port 4 6 1 3 Lubricate the adaptor seals and place them in the grooves of the adaptor Figure 2 15 Adaptor seals installation 8 Inch Side Port FRP Pressure Vessel User Manual Www ropv com cn 16 ROPI 4 6 2 Assemble the sealing plate and bearing plate 4 6 2 1 Assemble parted sealing plate Apply a thin layer of lubricant onto the surface of the permeate port and push the permeate port through the hole of the parted sealing plate 4 6 2 2 Insert the threaded end of the permeate port through the hole of the bearing plate until full contact of the sealing plate and bearing plate 4 6 2 3 Thread the permeate port locknut onto the threads of the permeate port Figure 2 16 Assembling parted seal plate
5. 5 2 2 Remove the adapter from the membranes on both sides of the vessel 5 3 Unload the membrane 5 3 1 Clean off any lubricant residue or salt build up from the inside diameter at both ends of the vessel 5 3 2 Remove the membrane out of the vessel according to the membrane manufacturer requirements Be careful not to scratch the inner surface of the vessel while removing or installing the membrane elements gt m pa Q pa 5 4 Check and make sure the head is assembled according to Head Disassembly and Head Assembly 8 Inch Side Port FRP Pressure Vessel User Manual 19 ROPI 5 5 Vessel cleaning and inspection Figure2 21 Side Port and vessel inspection 5 5 1 Clean the inner surface and groove of the vessel by removing the residue or corrosions with a mild soap solution and then flush with clean water 5 5 2 Check if there is any damage to the inner surface of the vessel If yes Please change the vessel 5 5 3 Carefully inspect the F C ports and the shell to ensure intact sealing structure and material Any questions please contact ROPV 5 6 Install the head at the concentration side 5 6 1 Apply a thin layer of glycerin within 50mm from the groove on the inner surface of the vessel at the concentrate downstream end of the vessel 5 6 2 Apply a thin layer of glycerin on the surface of the head O ring for the concentrate downstream end of the vessel 5 6 3 Install the
6. F C ports into the hole in the vessel from the inside the vessel and push them out Do not to scratch the inner surface of the vessel s side holes when installing F C ports until the retaining ring grooves are visible from the outside of the vessel D Install the retaining rings E Reconnect the pipes as per Piping Connections 8 5 Low Permeate Water Quality Possible reasons A O ring seals are damaged due to displaced membrane elements caused by frequent Starting and shutting down of the system without taking measures to ensure gradual pressure increase when starting and gradual pressure release when shutting down Solution a Remove the head as per Opening the Vessel and remove the adaptor b Replace the permeate port seals and adaptor seals c Close the vessel as per Loading Replacing Membrane Elements and Closing the vessel B Membranes may be displaced out of the sealing area during starting and shutting down the system 8 Inch Side Port FRP Pressure Vessel User Manual 31 ROPI Solution Shimming the membranes a Remove the head at feed end and adaptor as per Opening the vessel b Remove the adaptor seals and the head O ring Insert the straight end of the adaptor into the permeate hub far enough to be held by the adaptor sea Align the adaptor with the membrane and push the head carefully into the vessel until the groove is exposed far enough to insert a locking segment into it Slowly remove the he
7. Limited Warranty Harbin ROPV 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 30 days whichever is longer Exclusions from this Limited Warranty The warranty shall be void if 1 Defects are not 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 Problems caused by modification or alteration Chemical exposure or acts of nature Any item manufactured by other companies 6 Wear on replaceable components under normal conditions seals are excluded from this warranty DI a pa 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 ROPV s 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 t
8. required Misalignment in any direction should be avoided and keep to a minimum as much possible since it will generate mechanical stress concentrations that will damage the membrane housing 3 2 10 Verify the alignment There is a maximum of 0 76mm misalignment tolerance in any direction for all ports as shown in figure 1 3 Severe misalignment could impair the life expectancy of the vessel Excessive force to tighten the couplings is an indication of misalignment When properly aligned couplings should be able to turn slightly by hand after installation Maximum Misalignment 76mm 8 Inch Side Port FRP Pressure Figure 1 3 WWW ropv com cn 8 ROPI Chapter 4 Maintenance Guide 4 1 Preventive Maintenance Periodical cleaning and maintenance of the vessel and replacement of damaged components is essential to ensure a safe and normal operation of the vessel over a long service life As a recommendation we suggest to follow the Prevention Checklist below End closures e Periodically clean and remove any salt and or corrosion deposits e Inspect components for deterioration and replace as needed e Maintain external components dry and leak free Side Ports e Inspect for leakage e Inspect coupling connections for corrosion and replace deteriorated couplings as needed e Maintain all side ports dry and leak free to prevent corrosion Read this section completely before servicing the vessel DO NOT Service any component un
9. thrust ring onto the head for the concentrate downstream end of Figure2 22 Install the thrust ring 8 Inch Side Port FRP Pressure Vessel User Manual WWW rOpV com cn 20 ROPI the vessel 5 6 4 Grasp the permeate port and the locknut to keep the head and the vessel in the Same axis and push the head into the vessel until some resistance can be felt Then continue pushing the head slowly into the vessel until it reaches over the groove Please do not push the head too much over the groove since the seals may be damaged if the head needs to be pulled back If it is difficult to push the head with hands a rubber mallet can be used to hit the head until the head reaches its place 5 7 Install locking kit segment at concentration side 5 7 1 Inspect the groove and ensure it is clean and free of residues Use compressed air to dry the groove if available or use a clean rag to dry it 5 7 2 Apply lubricant like glycerin onto the locking kit segment screws to prevent salt deposits to buildup Position the locking kit segments into the groove Figure 2 23 Install locking kit segment 5 8 Load membrane elements from the feed end of the vessel 5 8 1 Inspect and confirm there are no scratches on the inner surface of the vessel 5 8 2 Inspect and ensure there is nothing on the outer surface of the membrane that may scratch the inner surface of the vessel 5 8 3 Using a clean rag or cotton and a mixture of glycerin
10. Checking packaging Temp 10 C 50 C Check storage conditions Humidi40 70 RH Light less than100Lux Check height Safe storage area Finish the storage Figure 2 27 Storage procedure 8 Inch Side Port FRP Pressure Vessel User Manual 271 ROPI Chapter 8 Breakdowns and Solutions Please refer to this article for common breakdowns and solutions The contents of this section need to be used with good practical industrial experience We recommend that only engineers with extensive work experience conduct any repair work 8 1 Locking Kit Segment and Related Issues 8 1 1 Locking kit segment screw is too tight to thread out Solution Apply penetrating fluid such as WD 40 or LPS 1 onto the locking kit segment and tap it with a hammer until the screw can be threaded off Please take care not to contaminate the membrane elements 8 1 2 Locking kit segment screw cannot be removed due to damage in screw cap or threads Solution cut the locking kit segment screw off Tools angle grinder cutting disc power cables electric drill M8 screw tap 6mm stainless steel drill bit Steps Cut the locking kit segment screw with angle grinder Use an electric drill with stainless steel bit with diameter of 6mm to drill the rest of the screw out of the bearing plate Please take care not to damage the threads of the screw hole in the bearing plate Make new threads for the screw hole in the bearing plate with a M8 screw tap F
11. Concentrate side ports in case of leakage A Shut down the system and drain the vessel Disconnect the piping off the permeate port and Feed Concentrate ports Open the vessel as per Opening the Vessel Remove the retaining ring from the leaking port mH o a w Using a rubber mallet tap the portin wards to remove the port When removing Feed Concentrate ports soft mats should be placed inside the vessel to keep the inner surface of the vessel from damaging by the falling F C ports NOI LNALV Possible reasons 1 Seals are damaged Solution replace the seals 2 Ports are corroded or damaged or the sealing groove is scratched Solution replace the Feed Concentrate ports 3 Ports and the manifolds are not in the same axis misaligned 8 Inch Side Port FRP Pressure Vessel User Manual 30 ROPI Solution adjust the manifolds and reconnect the pipes as per Piping Connections 8 2 7 Feed Concentrate Side Port Inspection and Installation Please follow steps below to install Feed Concentrate side ports A Clean ports Remove the fouling or residue on the F C ports with a mild soap solution and flush them with clean water Dry them with compressed air if available or a clean towel B Lubricate and install F C ports seals apply a thin layer of glycerin onto the seals and seat them into the grooves in the F C ports C Apply a thin layer of glycerin onto the inner side surface of the vessel s ports Insert the
12. Connect the vessel to the manifolds and or to the next vessel while adjusting each vessel and manifold to minimize misalignment at each end For details see Chapter 4 Piping Connections 2 7 Install the strap assembly Install the screws through the hole in the rack and thread them into the strap locknut use a torque wrench to tighten the screws within 3 5N m NOTE Pressure vessels expand during pressurization over tightening the strap assemblies will damage the vessel 2 8 Assemble end closure For details see Head Assembly in Maintenance Guide 2 9 Install membrane elements For details see Membrane Elements Installation in Maintenance Guide 2 10 Install thrust ring at the downstream end of the vessel 2 11 Close the vessel 2 12 Connect the permeate port manifolds For details see Piping Connections 2 13 Inspect the installation Inspection includes but is not limited to the position of the vessel the end caps and pipelines connections Please inspect according to Pre Pressurizing Checking list in Appendix 1 2 14 Pressurize and run the system If in doubt or for installation issues please contact ROPV 8 Inch Side Port FRP Pressure Vessel User Manual 60 ROPI Chapter 3 Piping Connections Enough room shall be reserved for both axial and radial expansion of the vessel in the design of the manifolds and pipelines otherwise the vessel and other components of the syste
13. Figure2 17 Assembling bearing plate using a wrench until the sealing plate and bearing plate are thoroughly contacted Figure 2 18 Locknut installation Figure 2 19 Adaptor installation 4 6 3 Install the adaptor Insert the end without seals into the hole of the permeate port 4 6 4 Install the head O ring Lubricate the O ring and seat it into the groove located on the outside diameter of the sealing plate 8 Inch Side Port FRP Pressure Vessel User Manual 17 Figure 2 20 Head assembly 8 Inch Side Port FRP Pressure Vessel User Manual 18 ROPI Chapter 5 Loading Replacing Membrane Elements Read all parts of this section before replacing membrane elements This article is for reference only load unload the membrane elements according to the membrane manufacturer requirements Membrane elements must be loaded at the feed upstream end of the vessel and unloaded through the concentrated downstream side of the vessel Always remove and install elements in the direction of feed flow Make a matching list for the removed membrane and the vessel to avoid possible disorder during membrane loading Steps 5 1 Inspection 5 1 1 Verify all pressure has been relieved from the vessel following system manufacturer s recommendations 5 1 2 Ensure the vessel is opened according to Opening the Vessel 5 2 Disassemble membrane components 5 2 1 Remove the thrust ring located at the concentration side
14. HARBIN ROPV INDUSTRY DEVELOPMENT CENTER ROPI 8 Inch Side Port FRP Pressure Vessel User Manual Models R8040B300S R8040B450S Headquarters Global Market Tel 86 451 82267301 Phone 1 925 237 0184 Fax 86 451 82267303 Fax 1 925 264 1951 Email ropv ropv com cn Email hwang ropv com cn Website www ropv com cn Website en ropv com cn en ROPI Table of Contents CHAPTER 1 GENERAL PRODUCT DESCRIPTION cccccceccsccccsccecccceccnccccsccnceccnccncecceccsceccecencecsecencucees 3 POC denne ai O Mae sre ate crs esate oretsacastsn voissttasnn E A 3 OPON SO GCI C AOS osc a secs cd ea cecteaac AS sac dexseceasnateananocagstencsed E N 4 Vessel Use and PFECAUL ONS iiscnsoe see inccdssccsceucinclasveldacecordsdewoucateajunbnckdeersasteeeienlessevdesasosesidannssadedealeedeerenstearevae 4 CHAPTER 2 INSTALLA TON sacsscecacseressse sia sosscunrtusasoutsecucsttansseduantaneuenevadeanas a 6 CHAPTER 3 PIPING CONNECTIONS scciscisncasiessicscanduunstacsasisnacsnces sacnuisstacenssaucesncesuewacsssnanenbsssuessnnasoanenbdoewass 7 Sole Permeate Port COnnectiON eessiaisre e a 7 3 2 Feed Concentrate Port CONNECTIONS cccccccsesecccecesscccceesececeeecececesececeucececaueececeuausesesauesessueceeeeaees 7 CHAPTER 4 MAINTENANCE GUIDE sissacescvsanccsatiecscntatescenncrebbentadunansnetcossatteass tates banieuesiaterlss sraaseisbuasmaiisuees 9 4 1 Preventive Maintenance ccceccsecsecsecsecsecsecseccuccecen
15. ad with care and then check the size of the gap between permeate port and adaptor The number of 2mm shims needed to fill this gap will depend on the size of the gap Reinstall the adaptor seals and seal plate seal slide shims on the flat end of the adaptor and insert the adaptor into the permeate port hub Shims must be placed between the permeate port and adaptor c Close the vessel as per Closing the Vessel 8 Inch Side Port FRP Pressure Vessel User Manual 32 ROPI Chapter 9 Service guide Dear users Thanks for choosing ROPV FRP pressure vessels We provide you with the following services according to our national laws and regulations See ROPV Limited Warranty for more details I Quality warranty ROPV promises to provide one year warranty and lifetime maintenance on the condition that the vessels are properly installed and operated II Technical suppport 1 ROPV commits to reply users within 8 hours for their complain or technical consultation 2 ROPV commits to arrive at project site within 48 hours if needed III Exclussions for the free service coverage 1 Damages caused by improper transportation installation operation and maintenance 2 Damages caused by operation without sticking to the requirements in this manual 3 Invoices are altered or Inspection Certificate is not available Any problem please contact via after sales hotline 0451 82267309 es Phone 0451 82267301 02 06 08
16. and clean water ata 1 1 ratio ball lubricate the inner surface of the vessel 5 8 4 Using a clean rag or cotton and a mixture of glycerin and clean water ata 1 1 ratio ball lubricate the membrane seal 5 8 5 Load the membrane from the feed end of the vessel ensure that the membrane is properly orientated If there are more than one membrane to be loaded into the vessel do not push the first membrane into the vessel completely but reserve around 200mm to facilitate the connection of the next membrane 8 Inch Side Port FRP Pressure Vessel User Manual 21 ROPI 5 8 6 Inspect and make sure the membrane interconnector is clean and intact Apply a thin layer of glycerin onto the interconnector seals without excessive amount otherwise the membrane may get contaminated Install the interconnector into the loaded membrane 5 8 7 Install and connect the next membrane with the loaded one with the interconnector 5 8 8 Load all membrane elements in the same way Push all the membranes into the vessel until the adaptor at the concentration end is inserted into the center hole of the first membrane and the membrane face is pushed against the thrust ring Please ensure all membranes are in the same axis No load on the connection pipe otherwise the pipe or the membrane may be damaged gt m a lt 8 Inch Side Port FRP Pressure Vessel User Manual 2 ROPI Chapter 6 Closing the Vessel Please
17. as shown in figure 1 1 Manifold ZE N IPS Grooved a a Manifold IPS Grooved ses O 0 ay ep L L O Pressure Vessel Pressure Vessel Sa 70 OVa r ae j l AHI JA x ae BM Q O Straight Connection 90 Bend Connection Figure 1 1 8 Inch Side Port FRP Pressure Vessel User Manual WWW rOpvV com cn 7 ROPI 3 2 6 The use of only one IPS standard coupling to connect directly to the manifolds is also acceptable However the welding of the manifolds and the installation position of the housing should be accurately controlled to ensure the proper alignment of the manifold and the Feed Concentrate ports 3 2 7 Install the vessel correctly Make sure to align the Feed Concentrate ports and the manifold ports at a distance of 3 17mm 3 2 8 Connecting the vessel and the manifold Since only one IPS coupling is used to connect directly to the manifold precautions shall be taken to ensure additional flexible space is provided for the connection of vessels and manifolds by adding an extra IPS coupling to the manifold as shown in figure 1 2 Pressure Vessel Distribution Manifold Single IPS Grooved A ee em ee rr MMM es eC es oes nT OES O R Intermediate IPS Grooved Coupling IPS Grooved Coupling Manifol Figure 1 2 3 2 9 Slight angle between manifolds and F C ports using IPS standard clamp for connection is acceptable However high accuracy in alignment is
18. e carefully Incorrect handling and storage may result in catastrophic failure Check the packing conditions when accepting the goods Contact the logistics company at once in case of damaged vessel Slight damage in the outer surface of the vessel within the painting layer is acceptable Any query please contact ROPV 7 1 Vessel Handling Precautions e Keep the vessel from falling down to the ground or colliding with other objects when it is being moved e Special care should be taken if forklift or other machinery is used for handling the vessel e Use padding to protect the vessels during handling to prevent damage e DO NOT Scratch or damage to the inner surface of the vessel e DO NOT lift the vessel from the Feed Concentrate ports or permeate ports e DO NOT impose excessive external force on the vessel e DONOT climb on the vessel e Damaged vessel must not be used 7 2 Storage Requirements e Donot store with other products e Make a list of product and spare parts before storage e Store vessels in their original packaging e Storage temperature range should be 102C 50 2C e Storage humidity range should be 40 70 RH e Store ina place with a light intensity of less than 100Lux e Store ina safe area to keep the vessel from shaking or falling e Height not exceeding 3 packing units 8 Inch Side Port FRP Pressure Vessel User Manual 26 Product quantity Checking Parts quantity
19. ecessueeceeseneces 21 CHAPTER 6 CLOSING THE VESSEL n eisciniicinsansceissi ninesini aa 23 CHAPTER 7 HANDLING AND SIORAGE ssesessesessesecscscssescececesereececececeroscececeseroecececererorcecererercecececeeeee 26 8 Inch Side Port FRP Pressure Vessel User Manual 1 ROPI 7 1 Vessel Handling Precautions ccscscssresscssrcscsssscsssescussesteustecessscsssencustenscsesvscssneusrencustsenesssscusrenens 26 7 2 Storage Requirements cccscssecesccesccsecoecesecesecsecesecesecsecessssecesesseesseceesteecesstaeceesessesscesseascesseaeceess 26 CHAPTER 8 BREAKDOWNS AND SOLUTIONG ccscsccsccscsccsccsceccncssceccecenceccecencncsececcncsececcnssscesenes 28 8 1 Locking Kit Segment and Related ISSUCS ccccssccccssseccesececeneceeeneeeeeesceseeecessneceeeaeeeeeeecessecetsneeeeens 28 8 2 Head and Related ISSUCS sscpctesccccncstvesnetataseubsseaewssiecoreddnevae cueesoseeieaugekdetunseutdbiweseleseesysieresestegcansetecaewes 28 8 3 Vesseland Related SSUES inssin a aa ne ee 29 8 4 Feed Concentrate Side Ports and Related ISSUCS cccccecessecceccessececeusececceeecescesesececauesessuneceseneees 30 Bs HOW OUI Ce Water Qualy scot Src enneren a EA 31 CHAPTER 9 SERVICE GUND Ey iaicstccacencanchaciatcasseasanmaunastussadeetuucseiebcasnedcducctinusshinusinasstensia aeaa aa 33 APP NAN aria er ae ee ee EA ee 34 PU PRIN MN C NECKE ge ccc rr citar E AE EA SEES ca o
20. ecsessecsecsecuceuceuctsessesseeeseceuceeceusesessesseseseeseeees 9 rl Mme 1021 0 EAE E A A ce en er ee ee A eee eee ee 9 4 3 Head DISASSCMDIMNG axicccesainmscasivesacadeeresatdanntisietegedsdnasecataaunntecebesedsbecaeistdusadestesnnedsanstecasanevatarevapodagaances 12 4 4 Head Assembly Cleaning and INSPECTtION ccccccssecccesseccesecccenececenececeeeceseeceseeceseuseeseuecesseceneness 14 4 5 Cleaning and Inspection of the non metallic COMPONENMS ccccccessccceeessececeesececceeececeeeeseceeaeneees 15 4O Head As SeMOl V einiino E E E a N E E 15 CHAPTER 5 LOADING REPLACING MEMBRANE ELEMENTS sccsccececceccececcececceccececcecsececcscsecsccnes 19 SL ADEC UON nn ar ne ere Pree E eee eer ee eer 19 5 2 Disassemble membrane components sssssessseessreressrrssrrssrrrssrrssrrressrrssreesrersreresrersseeeseereseeeseerseeeese 19 Co IO TINS EeNNN eaea E E 19 5 4 Check and make sure the head is assembled according to Head Disassembly and Head Assembly 19 Deo Vecseldedanne and ISOC LON eai a aE E 20 5 6 Install the head at the concentration sid ssssesssenseseesseerssrrssrrssrrreserrsseresrersrrrssrressrersrerssereseerse 20 5 7 Install locking kit segment at concentration SIGE ssssusseesesenssrressrersrrrssressrrrssrrrssrresereserresrreserersee 21 5 8 Load membrane elements from the feed end of the vessel ccccceeseccceeesececeeeeceeees
21. elt Push the head Slowly into the vessel until it reaches over the groove Please do not push the head too much over the groove since the seals may be damaged if the head needs to be pulled back If it is difficult to push the head with hands a rubber mallet can be used to hit the head until the head reaches its place Figure2 25 Install head assembly 6 3 Install locking kit segment at feed end 6 3 1 Inspect the groove and ensure it is clean and free of residues Use compressed air to dry the groove if available or use a clean rag to dry it 6 3 2 Apply lubricant like glycerin onto the locking kit segment screws to prevent salt deposits to buildup Position the locking kit segments into the groove 6 4 Install the permeate port plug 8 Inch Side Port FRP Pressure Vessel User Manual WWW FrOpvV com cn 24 ROPI Apply Teflon sealing tape on the threads of the plug not exceeding 2 layers before threading it into the perm port Over tightening may damage the permeate port Maximum torque is 15Nm Tighten plug at 50 of the maximum torque The end face of the plug should be 3mm higher than the permeate port face 6 5 Reconnect the pipes Figure 2 26 Install permeate port plug Reconnect the pipes as per Piping Connections 6 6 Check as per Appendix I Pre Running Check List 8 Inch Side Port FRP Pressure Vessel User Manual WWW ropv com cn 25 ROPI Chapter 7 Handling and Storage Read this articl
22. est 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 ROPV 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 conduct 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 ot
23. her 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 other 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 8 Inch Side Port FRP Pressure Vessel User Manual OOOO OWA TO CO 36
24. il a smooth finish is achieved For dip damage or scratches not affecting the structural wall 2mm epoxy or vinyl ester resin can be used to fill the damaged surface 8 2 5 Vessel is corroded or cracked Possible reasons A Ph out of range medium is to acid or alkaline B Non acid membrane shells mixed with acid proof membrane shell Solution a Inspect the cracks If it is a high pressure vessel or the cracks reach structural layer 2mm deep the vessel must be replaced b Check the medium Check the PH range and adjust accordingly 8 2 6 Body damage A During transportation B During installation 8 Inch Side Port FRP Pressure Vessel User Manual 29 ROPI Solution replace the vessel if the body is seriously damaged measures below can be taken if there is only slight damage Tools painting gun air compressor electric dryer angel sander and sanding disc louver blade Materials Epoxy resin and hardener body filler and hardener ROPV paint fiberglass mat Steps First use epoxy resin mats fiberglass mat to fill the damage once the resin is cured sand the excess until the surface is level and smooth apply body filler if necessary last paint with a painting gun For any leakage of Feed Concentrate port please contact Harbin ROPV Industry Development Center gt EE Z pmr Z 8 4 Feed Concentrate Side Ports and Related Issues Please follow steps below to remove Feed
25. lush the residue with clean water Take care not to damage bearing plate vessel and permeate port during cutting Helmet and mask must be used for protection D gt m 8 2 Head and Related Issues 8 2 1 Leakage in seals Possibilities A Deteriorated head seals after running for over 2 years B Seals are damaged due to improper installation C Seals are deformed due to the PH of the medium D Seals are deformed due to the temperature of the medium Solution 8 Inch Side Port FRP Pressure Vessel User Manual 28 ROPI a Check the composition temperature and PH of the medium b Replace the seals as per Maintenance Guide 8 2 2 Sealing plate or permeate portis damaged Solution Replace sealing plate or permeate port There should be no more than 4 layers of seal tape on the permeate port threads It is better to use PVC tubing to connect to the permeate port rather than stainless steel Threads of the tube that connects the permeate port must be in match with those of permeate port D gt m a 8 2 3 Bearing plate is corroded due to leakage in vessel Solution Repair the leakage and replace bearing plate as per Vessel and Related Issues 8 3 Vessel and Related Issues 8 2 4 Leakage in sealing surfaces Possible reasons Scratches or damaged bore at the seal area location Solution For lite scratches hand sand sealing areas using wet 600grit sand paper unt
26. m could be damaged There are some location deviation about feed concentrate ports and permeate ports connecting consider these deviation when design the piping connection otherwise the stress concentration may damage the pipe Careful reading of this chapter will facilitate safe and normal working conditions of the vessel and pipelines 3 1 Permeate Port Connections 3 1 1 Use flexible connections to reduce vibration impact 3 1 2 A U swan neck tubing with flexible connectors at both ends or one piece of flexible soft pipe should be used for permeate port connections 3 1 3 Extra and independent support shall be provided for permeate port pipelines rather than using permeate port as support Note To prevent damage to the permeate port do not tighten the permeate port conections over 50N m of torque 3 2 Feed Concentrate Port Connections 3 2 1 Use flexible grooved couplings IPS 3 2 2 Do not connect any manifolds rigidly to the vessel 3 2 3 Manifolds must be supported independently 3 2 4 Manifold span should be greater than vessel span to allow for vessel growth under pressure 3 2 5 To reduce the risk of stress concentration we recommend that two IPS standard flexible couplings and one piping section are used to connect the Feed Concentrate ports and manifold ports this method lowers requirements for housing alignment and the position accuracy of the manifold welds However this method will increase the initial cost
27. meate port plug permeate port locknut seals 8 Inch Side Port FRP Pressure Vessel User Manual WWW FOpV com cn 13 Figure 2 12 Head breakdown figure 2 parted sealing plate Components sealing plate permeate port adaptor bearing plate plug permeate port locknut seals 4 4 Head Assembly Cleaning and Inspection Please read this section carefully before making decisions and taking measures on component structure or corrosion problems Please combine the operational experience with this manual to deal with corrosion and component damage You can refer to lt Breakdowns and solutions gt for the content that is not included in this section or contact ROPV for conditions not covered in this manual 4 4 1 Cleaning and Inspection of the metallic components Metallic components include the aluminum bearing plate stainless steel locking kit segments and screws 4 4 2 Inspect the components for scale salt deposit or corrosion use a steel brush or a scrubbing pad to loosen any deposit Be careful not to scratch the bearing plate anodize coating 4 4 3 Place the components into a vessel filled with mild soap solution and remove the corrosion 4 4 4 Flush all components with clean water 4 4 5 Dry the components with compressed air or a clean and dry towel 4 4 6 Inspect all components carefully check for any structural defects or damage in the bearing plate anodized coating Replace any damaged or defective component
28. moval tool set is available from ROPV While not necessary for head removal they have proven an effective and easy way to remove the vessel head without causing any damage to the vessel There are four components bearing block position nut bearing rod center piece Figure 2 2 ROPV Head Removal Tool 8 Inch Side Port FRP Pressure Vessel User Manual 10 ROPI 4 2 6 1 1 Thread the center piece into the permeate port of the head assembly to hand tight Do not over tighten the center piece Fig 2 3 4 2 6 1 2 Place the bearing block at the end face Figure 2 3 Figure 2 4 4 2 6 1 3 Thread the position nut into the center piece 4 2 6 1 4 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 4 2 6 2 Alternative Head Removal It is possible to remove the head assembly without the ROPV head removal tools A 1 NPT Male threaded piece of PVC or Figure 2 5 Figure 2 6 similar material pipe should be threaded into the head permeate port to hand tightness Pull the pipe outward to remove the head If the vessel has been in operation for an extended time a slight rocking motion or forceful tug may be required to break the head seal bond Also a handle at the end of the pipe will ease head removal forming a T with the pipe that threads into the permeate port
29. read this article carefully Incorrect assembly may result in catastrophic failure 6 1 Pre Closing Inspection Please read this article before closing the vessel DO NOT use corroded or damaged parts to avoid catastrophic failure Do not pressurize the vessel before all closing steps are finished 6 1 1 Inspect the head is assembled as per Head Disassembly and Head Assembly 6 1 2 Verify that the membranes are loaded as per Loading Replacing Membrane Elements 6 1 3 Ensure the inner surface of the vessel is free of corrosion build up or residue of foreign materials Figure 2 24 Vessel cleaning 6 1 4 Inspect and make sure there are no scratches or damage on the inner surface of the vessel 6 1 5 Inspect the vessel groove and make sure there are no residues or salt buildup in it 6 1 6 Inspect the Feed Concentrate port connections and vessel make sure the seals are intact structurally sound and free of corrosion If you have any questions or find any adverse situation please contact ROPV 8 Inch Side Port FRP Pressure Vessel User Manual 23 ROPI 6 2 Install head at the feed end upstream 6 2 1 Apply a thin layer of glycerin within 50mm from the groove on the inner surface of the vessel 6 2 2 Apply a thin layer of glycerin onto the head O ring at feed end 6 2 3 Grasp the permeate port and locknut keep head and vessel in the same axis Push the head into the vessel until some resistance can be f
30. 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 must be non load bearing e Mount vessel using strap saddle hardware provided and span recommended in 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 e Align the side 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 are suggested in case of corrosion e Thrust Ring must be installed at the downstream end of the vessel e Relieve system pressure before working on the vessel 8 Inch Side Port FRP Pressure Vessel User Manual 4 ROPI e 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 e Never operate the vessel in excess of its ratings This may void the warranty and cause bodil
31. til you verify that system pressure is fully relieved from the vessel and the system is completely shut down 4 2 Opening the Vessel 4 2 1 Shut Down System and Relieve System Pressure The system must be shut down and all pressure relieved before conducting any maintenance or repair on the vessel Read and follow all related guides provided by system provider 4 2 2 Disconnect permeate port piping Unscrew and remove the permeate port piping using a wrench Pay attention to the thread turning direction to prevent any damage to the permeate port due to reversed turning or over turning 4 2 3 Inspect End Closure The end closure should be inspected for any signs of corrosion or damage Surface corrosion and salt deposits can be removed with a 8 Inch Side Port FRP Pressure Vessel User Manual 9 ROPI brush or scrubbing pad while flushing with water Damaged components should be replaced with approved components from ROPV 4 2 4 Remove the locking kit segment screws using a hex wrench Figure 2 1 4 2 5 Lift the locking kit segment out of the retaining groove using a screw driver 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 Remove the end closure It is recommended to use dedicated end closure removal tools from ROPV 4 2 6 Remove the Head Assembly with One of the Following Techniques 4 2 6 1 ROPV Head Removal Tool A head re
32. ut EE 34 APP RAD ere nee een ers oe tr ee E ee eee ee ae 35 PVA TN OCC IS orea r ice vincent E carers E EEA E 35 PROP URCA WY Girl A Y eE anew aaece sean eelouvaeaous sonata sesaie dia eaioceouavsoersoteenadeavenoious E E 36 8 Inch Side Port FRP Pressure Vessel User Manual 2 ROPI Chapter 1 General Product Description ROPV pressure vessel is designed to withstand 6 times the designed pressure before a catastrophic failure occurs As a safety precaution the housings are designed for a full body leak at 4 times the design pressure to keep catastrophic failure from happening Each standard vessel is carefully inspected and a hydro test is performed to ensure its reliability before delivering from the plant 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 improperly installed operated or maintained Read and understand all guidelines 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 ROPV Pressure Vessels are design and manufacture in accordance
33. with the American Society of Mechanical Engineers ASME Section X Boiler and Pressure vessels Code requirements for use as a membrane element housing Product Identification R 8040 B 300 S 6 W ROPV L Paint Color White 8 Inch Diameter Membranes per Vessel Membrane Feed Concentrate Membrane Length Side Port Connection 40 Inch Maximum Operating B Series Pressure PSI R 8040 B 300 E 6 B L Paint Color Blue Feed Concentrate End Port Connection 8 Inch Side Port FRP Pressure Vessel User Manual WWW rOpvV com cn 3 ROPI Operation Specifications R80 300E Design Pressure 300PSI 2 1Mpa 21Bar R80 450E Design Pressure A50PSI 2 1Mpa 21Bar Max Permeate Pressure 125PSI 0 86Mpa 8 6 Bar Min Operating Temp 14 F 10 C Max Operating Temp 150 F 66 C Factory Test Pressure ASME 1 1x Design Pressure Standard 1 5x Design Pressure Operating pH Range 3 11 Cleaning pH Range 2 12 less than 30 minutes Vessel Use and Precautions e Do not allow the vessel to fall or impact on the ground or other object e Use padding to protect the vessels during handling to prevent damage e Pressure up to the design pressure PSI of the specific model being used e Vacuum conditions should be avoided with vacuum breakers e Accommodates standard 8 nominal diameter spiral wound elements e Read and follow the membrane manufacturer installation instructions along with this manual e The
34. y 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 e Do not install the vessel under direct sunlight e Operate the vessel within the recommended pH range Operating pH Range 3 10 Cleaning pH Range 2 12 less than 30 minutes e Minimize membrane movement by careful shimming the membrane column e Failure to understand and follow all precautions may void warranty and result in catastrophic failure of the vessel e These guidelines are subject to change Please check with ROPV to ensure that the User Manual is the latest version for the vessel model being used 8 Inch Side Port FRP Pressure Vessel User Manual 5 ROPI Chapter 2 Installation 2 1 Carefully study the vessel engineering drawings for key dimensions and technical requirements 2 2 Design and manufacture rack according to engineering drawings and system capacity Independent support of both pressure vessel and manifolds shall be considered in the design of the rack 2 3 Check the integrity of the vessel especially the inner surface of the vessel and the sealing surface of the Feed Concentrate ports 2 4 Ensure enough space is reserved around the two ends of the vessel for installation and removal of the membrane elements 2 5 Mount the vessel on the provided saddles at the recommended span positions shown on the engineering drawings 2 6
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