Manual For Vessels
Manual For Vessels
Manual For Vessels
User Manual
Models:
R8040B600S/R8040B1000S/R8040B1200S
Table of Contents
CHAPTER 1 GENERAL PRODUCT DESCRIPTION ....................................................................................... ‐ 3 ‐
Product Identification .................................................................................................................................... ‐ 3 ‐
Operation Specifications ............................................................................................................................... ‐ 4 ‐
Vessel Use and Precautions ........................................................................................................................... ‐ 4 ‐
CHAPTER 2 INSTALLATION ..................................................................................................................... ‐ 6 ‐
CHAPTER 3 PIPING CONNECTIONS ......................................................................................................... ‐ 7 ‐
3.1. Permeate Port Connections................................................................................................................. ‐ 7 ‐
3.2. Feed/Concentrate Port Connections ................................................................................................... ‐ 7 ‐
CHAPTER 4 MAINTENANCE GUIDE ......................................................................................................... ‐ 9 ‐
4.1. Preventive Maintenance ..................................................................................................................... ‐ 9 ‐
4.2. Opening the Vessel .............................................................................................................................. ‐ 9 ‐
4.3. Head Disassembling ........................................................................................................................... ‐ 12 ‐
4.4. Head Assembly Cleaning and Inspection. .......................................................................................... ‐ 13 ‐
4.5. Cleaning and Inspection of the non‐metallic components. ............................................................... ‐ 14 ‐
4.6. Head Assembly .................................................................................................................................. ‐ 14 ‐
CHAPTER 5 LOADING/REPLACING MEMBRANE ELEMENTS .................................................................. ‐ 18 ‐
5.1. Inspection .......................................................................................................................................... ‐ 18 ‐
5.2. Disassemble membrane components ............................................................................................... ‐ 18 ‐
5.3. Unload the membrane ...................................................................................................................... ‐ 18 ‐
5.4. Check and make sure the head is assembled according to Head Disassembly and Head Assembly. ‐ 18 ‐
5.5. Vessel cleaning and inspection .......................................................................................................... ‐ 18 ‐
5.6. Install the head at the concentration side ......................................................................................... ‐ 19 ‐
5.7. Install locking kit segment at concentration side. ............................................................................. ‐ 20 ‐
5.8. Load membrane elements from the feed end of the vessel ............................................................. ‐ 20 ‐
CHAPTER 6 CLOSING THE VESSEL ......................................................................................................... ‐ 22 ‐
CHAPTER 7 HANDLING AND STORAGE ................................................................................................. ‐ 24 ‐
CHAPTER 8 BREAKDOWNS AND SOLUTIONS ........................................................................................ ‐ 26 ‐
8.1. Locking Kit Segment and Related Issues. ........................................................................................... ‐ 26 ‐
8.2. Head and Related Issues. ................................................................................................................... ‐ 26 ‐
8.3. Vessel and Related Issues. ................................................................................................................. ‐ 27 ‐
8.4. Feed/Concentrate Side Ports and Related Issues. ............................................................................. ‐ 28 ‐
8.5. Low Permeate Water Quality ............................................................................................................ ‐ 29 ‐
CHAPTER 9 SERVICE GUIDE .................................................................................................................. ‐ 31 ‐
Appendix I .................................................................................................................................................... ‐ 32 ‐
Pre‐ Running Check List ............................................................................................................................... ‐ 32 ‐
Appendix II ................................................................................................................................................... ‐ 33 ‐
Maintenance Check List ............................................................................................................................... ‐ 33 ‐
ROPV Limited Warranty ............................................................................................................................... ‐ 34 ‐
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 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 80 40 B 300 S ‐ 6 (W)
R 80 40 B 300 E ‐ 6 (B)
Operation Specifications
R80 600S Design Pressure: 600 PSI / 4.1Mpa / 41 Bar
R80 1000S Design Pressure: 1000PSI / 6.9Mpa / 69 Bar
R80 1200S Design Pressure: 1200PSI / 8.3Mpa / 83 Bar
Max. Permeate Pressure: 125PSI / 0.86Mpa / 8.6 Bar
Min. Operating Temp.: 14⁰F / ‐10⁰C
Max. Operating Temp.: 150⁰F / 66⁰C
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)
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. 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.
Straight
Figure 1.1
also acceptable. However, the welding of the manifolds and the installation position
Figure 1.2
Figure 1.3
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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.
Periodically clean and remove any salt and/or corrosion deposits.
Inspect components for deterioration and replace as needed.
Maintain external components dry and leak free.
Side Ports.
Inspect for leakage.
Inspect coupling connections for corrosion and replace deteriorated couplings as
needed.
Maintain all side ports dry and leak free to prevent corrosion.
WARNING
Read this section completely before servicing the vessel.
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
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 removal 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.
without the ROPV head removal tools. A 1” NPT Male threaded piece of PVC (or
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.
removed.
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.
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 <Breakdowns and solutions> 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.
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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.
4.6.1.1. Lubricate the permeate port seals and place them in the grooves.
4.6.1.2. 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 2.16 Assembling parted seal plate Figure2.17 Assembling bearing 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
using a wrench until the sealing plate and bearing plate are thoroughly
contacted.
4.6.2.4. Install the adaptor. Insert the end without seals into the hole of the
permeate port.
4.6.2.5. Install the head O‐ring. Lubricate the O‐ring and seat it into the groove
located on the outside diameter of the sealing plate.
5.4. Check and make sure the head is assembled according to Head Disassembly and
Head Assembly.
5.5. Vessel cleaning and inspection
5.5.1. Clean the inner surface and groove of the vessel by removing the residue or
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.
Warning
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.
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.
6.1.7. Shimming the membranes. Due to variation on the length of the membranes
and the vessel tolerance, shimming might be necessary to prevent membrane
movement during operation.
6.1.7.1. 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 seal.
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 head 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
6.2. Install head at the feed end (upstream)
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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 felt. 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.
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.
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
Product quantity
Checking
Parts quantity
Checking packaging
Temp.‐10ºC~+50 ºC
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)
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.
Phone: 0451‐82267301/02/06/08
E‐mail: [email protected]
Website: www.ropv.com.cn
Appendix I
Pre‐ Running Check List
Items Status
Membrane
Adaptor is installed as per requirements YES□ NO□
elements
Appendix II
Maintenance Check List
Times of
Running time
maintenance
Inspector: Inspection date: