harbin ropv industry development center

HARBINROPVINDUSTRYDEVELOPMENTCENTER

8InchEndPortFRPPressureVessel

UserManual

Models:

R8040B300E/R8040B450E

HeadquartersTel：(+86)451‐82267301Fax：(+86)451‐82267303Email:[email protected]:www.ropv.com.cn

GlobalMarketPhone：(+1)925‐237‐0184Fax：(+1)925‐264‐1951Email:[email protected]:en.ropv.com.cn/en

8InchEndPortFRPPressureVesselUserManual

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TableofContents

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. .......................................................................................................................... ‐ 11 ‐

4.4. Head Assembly Cleaning and Inspection. .......................................................................................... ‐ 13 ‐

4.5. 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 .......................................................................................................... ‐ 19 ‐

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 ‐

7.1. Vessel Handling Precautions .............................................................................................................. ‐ 24 ‐


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7.2. Storage Requirements ....................................................................................................................... ‐ 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 ............................................................................................................ ‐ 28 ‐

CHAPTER 9 SERVICE GUIDE .................................................................................................................. ‐ 30 ‐

Appendix I .................................................................................................................................................... ‐ 31 ‐

Pre‐ Running Check List ............................................................................................................................... ‐ 31 ‐

Appendix II ................................................................................................................................................... ‐ 32 ‐

Maintenance Check List ............................................................................................................................... ‐ 32 ‐

ROPV Limited Warranty ............................................................................................................................... ‐ 33 ‐


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Chapter1 GeneralProductDescription

ROPV pressure vessel is designed to withstand 6 times the designed pressure before acatastrophic failureoccurs.Asasafetyprecaution thehousingsaredesigned fora fullbodyleak at 4 times the design pressure to keep catastrophic failure from happening. Eachstandardvessel iscarefully inspectedandahydro‐test isperformed toensure its reliabilitybeforedeliveringfromtheplant.ROPV Pressure Vessels are designed to provide safe operation over a long service life ifproperlyinstalled,operated,andmaintained.Thevesselmaycauselossoflife,severebodilyharm, or property damage if improperly installed, operated, or maintained. Read andunderstand all guidelines provided in the vessel User Manual. Observe every precautioncontained therein. Failure to do so may result in malfunction and potential catastrophicfailure. It isrecommendedthatonlyqualifiedtechniciansexperiencedinservicinghydraulicsystems work with this vessel. Misuse, incorrect assembly, or use of damaged/corrodedcomponents may result in catastrophic failure. ROPV Pressure Vessels are design andmanufactureinaccordancewiththeAmericanSocietyofMechanicalEngineers,ASME,SectionXBoilerandPressurevesselsCoderequirements,foruseasamembraneelementhousing.

ProductIdentification

ROPV

R 8040 B 300 S ‐ 6 (W)

8InchDiameterMembrane

MembraneLength40Inch

BSeries

MembranesperVessel

PaintColorWhite

Feed/ConcentrateSidePortConnection

MaximumOperatingPressure(PSI)

R 8040 B 300 E ‐ 6 (B)

PaintColorBlue

Feed/ConcentrateEndPortConnection


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OperationSpecifications

R80300EDesignPressure: 300PSI/2.1Mpa/21BarR80450EDesignPressure: 450PSI/2.1Mpa/21BarMax.PermeatePressure: 125PSI/0.86Mpa/8.6BarMin.OperatingTemp.: 14⁰F/‐10⁰CMax.OperatingTemp.: 150⁰F/66⁰CFactoryTestPressure: ASME:1.1xDesignPressure

Standard:1.5xDesignPressureOperatingpHRange: 3–11CleaningpHRange: 2–12(lessthan30minutes)

VesselUseandPrecautions

Donotallowthevesseltofallorimpactonthegroundorotherobject. Usepaddingtoprotectthevesselsduringhandlingtopreventdamage. Pressureuptothedesignpressure(PSI)ofthespecificmodelbeingused. Vacuumconditionsshouldbeavoidedwithvacuumbreakers. Accommodatesstandard8”nominaldiameterspiral‐woundelements. Readandfollowthemembranemanufacturerinstallationinstructionsalongwiththismanual. The requiredvessel/element interfacehardware is suppliedwith thevessel.Ensure thatan

elementadapterisinstalledateachendofthevesselbeforeuse. Vessel expands under pressure and careful consideration must be taken when installing

straps/saddlesandsystemconnectionpiping. Installationwiththestraps/saddlesprovidedisstronglyrecommended Vessel should not support any other system components. Connections must be non‐load

bearing. Mount vessel using strap/saddle hardware provided and span recommended in the

engineeringdrawing. Donotovertightenthestraps–vesselmustbeallowedtoexpandunderoperation. Maximizetheconnectionflexibilitytoallowforvesselgrowthunderpressure. Align the side ports with the system manifold, correcting any misalignment before final

installation. Provideoverpressureprotectioninthesystemsafetydevices. Inspect end closures regularly for signs of corrosion. Immediate corrective action and/or

replacementaresuggestedincaseofcorrosion. ThrustRingmustbeinstalledatthedownstreamendofthevessel. Relievesystempressurebeforeworkingonthevessel.


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Donot attempt to over‐tighten thePermeatePort connections as thismaydamage the endclosure.Oneturnpasthandtightshouldbesufficient.

Neveroperatethevesselinexcessofitsratings.Thismayvoidthewarrantyandcausebodilyorpropertydamage.

Donotoperatethevesselpermeateportover125PSI. Flushthevesselwithpermeatebeforesystemshutdowntoreducethechanceofcorrosion. Donotinstallthevesselunderdirectsunlight. OperatethevesselwithintherecommendedpHrange‐OperatingpHRange:3–10,Cleaning

pHRange:2–12(lessthan30minutes). Minimizemembranemovementbycarefulshimmingthemembranecolumn. Failuretounderstandandfollowallprecautionsmayvoidwarrantyandresultincatastrophic

failureofthevessel. These guidelines are subject to change. Please check with ROPV to ensure that the User

Manualisthelatestversionforthevesselmodelbeingused.


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Chapter2 Installation2.1. Carefully study the vessel engineering drawings for key dimensions and technical

requirements.2.2. Designandmanufacturerackaccordingtoengineeringdrawingsandsystemcapacity.

Independentsupportofbothpressurevesselandmanifoldsshallbeconsideredinthedesignoftherack.

2.3. Check the integrity of the vessel, especially the inner surface of the vessel and thesealingsurfaceoftheFeed/Concentrateports.

2.4. Ensureenoughspaceisreservedaroundthetwoendsofthevesselforinstallationandremovalofthemembraneelements.

NOTE: InstallthevesselscenteredontheracktoavoidstressconcentrationontheFeed/Concentrateports.2.5. Mountthevesselontheprovidedsaddlesattherecommendedspanpositionsshown

ontheengineeringdrawings.2.6. Connect the vessel to themanifolds and/or to the next vesselwhile adjusting each

vesselandmanifoldtominimizemisalignmentateachend.(Fordetails,see“Chapter4PipingConnections”).

2.7. Installthestrapassembly.Installthescrewsthroughtheholeintherackandthreadthemintothestraplocknut;useatorquewrenchtotightenthescrewswithin3~5N.m.NOTE:Pressurevesselsexpandduringpressurization,overtighteningthestrapassemblieswilldamagethevessel.

2.8. Assembleendclosure(Fordetails,see“HeadAssembly”in“MaintenanceGuide”)2.9. Install membrane elements(For details, see “Membrane Elements Installation” in

“MaintenanceGuide”)2.10. Installthrustringatthedownstreamendofthevessel.2.11. Closethevessel.2.12. Connectthepermeateportmanifolds(Fordetails,see“PipingConnections”)2.13. Inspect the installation. Inspection includesbut isnot limited tothepositionof the

vessel, the end caps and pipelines connections. Please inspect according to “Pre‐PressurizingCheckinglist”inAppendix1.

2.14. Pressurizeandrunthesystem.Ifindoubtorforinstallationissues,pleasecontactROPV.


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Chapter3 PipingConnectionsEnoughroomshallbereservedforbothaxialandradialexpansionof thevessel inthedesignofthe

manifoldsandpipelines;otherwisethevesselandothercomponentsofthesystemcouldbedamaged.

There are some location deviation about feed\concentrate ports and permeate ports connecting,

considerthesedeviationwhendesignthepipingconnection,otherwisethestressconcentrationmay

damagethepipe.Carefulreadingofthischapterwillfacilitatesafeandnormalworkingconditionsof

thevesselandpipelines.

3.1. PermeatePortConnections

3.1.1. Useflexibleconnectionstoreducevibrationimpact.

3.1.2. AUswan‐necktubingwithflexibleconnectorsatbothends,oronepieceofflexiblesoftpipe

shouldbeusedforpermeateportconnections.

3.1.3. Extraand independentsupportshallbeprovided forpermeateportpipelinesrather than

usingpermeateportassupport.

Note:Topreventdamage to thepermeateportdonot tighten thepermeateport conections

over50N.moftorque.

3.2. Feed/ConcentratePortConnections

3.2.1. Useflexiblegroovedcouplings(IPS).3.2.2. Donotconnectanymanifoldsrigidlytothevessel.

3.2.3. Manifoldsmustbesupportedindependently.

3.2.4. Manifold span should be greater than vessel span to allow for vessel growth under

pressure.

3.2.5. Toreducetheriskofstressconcentrationwerecommendthat“twoIPSstandardflexible

couplings and one piping section” are used to connect the Feed/Concentrate ports and

manifoldports; thismethodlowersrequirements forhousingalignmentandtheposition

accuracy of the manifold welds. However, this method will increase the initial cost as

showninfigure1.1.

Figure1.1

90⁰BendConnection

Manifold

IPSGrooved

PressureVessel PressureVessel

IPSGroovedManifold

StraightConnection


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MaximumMisalignment.76mm

Figure1.3

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 themanifold

andtheFeed/Concentrateports.

3.2.7. Install the vessel correctly: Make sure to align the Feed/Concentrate ports and the

manifoldportsataright distance.Please contact the supplier of coupling to get the exact distance.

3.2.8. Connecting the vessel and themanifold: Since only one IPS coupl i n g i s u s e d t o connect directly to themanifold precautions shall be taken to ensure additional flexiblespace is provided for the connection of vessels and manifolds by adding an extra IPS

couplingtothe

manifold,asshowninfigure1.2.

3.2.9. SlightanglebetweenmanifoldsandF/CportsusingIPSstandardclampforconnectionis

acceptable.However,highaccuracyinalignmentisrequired.Misalignmentinanydirection

should be avoided and keep to a minimum as much possible since it will generate

mechanicalstressconcentrationsthatwilldamagethemembranehousing.

3.2.10. Verify the alignment: There is a maximum of 0.76mm misalignment tolerance in any

direction forallportsas shown in figure1.3. Severemisalignment could impair the life

expectancy of the vessel. Excessive force to tighten the couplings is an indication of

misalignment.Whenproperlyalignedcouplings shouldbeable to turn slightlybyhandafterinstallation.

Figure1.2

DistributionManifoldPressureVessel

SingleIPSGrooved

ManifolIntermediateIPSGroovedCoupling IPSGroovedCoupling


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Chapter4 MaintenanceGuide4.1. PreventiveMaintenance

Periodical cleaning and maintenance of the vessel and replacement of damaged components is

essentialtoensureasafeandnormaloperationofthevesseloveralongservicelife.

AsarecommendationwesuggesttofollowthePreventionChecklistbelow:

Endclosures.

Periodicallycleanandremoveanysaltand/orcorrosiondeposits.

Inspectcomponentsfordeteriorationandreplaceasneeded.

Maintainexternalcomponentsdryandleakfree.SidePorts.

Inspectforleakage.

Inspectcouplingconnectionsforcorrosionandreplacedeterioratedcouplingsasneeded.

Maintainallsideportsdryandleakfreetopreventcorrosion.

4.2. OpeningtheVessel

4.2.1. ShutDownSystemandRelieveSystemPressure–Thesystemmustbeshutdownandall

pressurerelievedbeforeconductinganymaintenanceorrepaironthevessel.Readand

followallrelatedguidesprovidedbysystemprovider.

4.2.2. Disconnectpermeateportpiping.Unscrewandremovethepermeateportpipingusinga

wrench.Payattentiontothethread‐turningdirectiontopreventanydamagetothe

permeateportduetoreversedturningorover‐turning.

4.2.3. InspectEndClosure–Theendclosureshouldbeinspectedforanysignsofcorrosionor

damage.Surfacecorrosionandsaltdepositscanberemovedwithabrushorscrubbing

pad,whileflushingwithwater.Damagedcomponentsshouldbereplacedwithapproved

componentsfromROPV.

4.2.4. Removethelockingkitsegmentscrewsusingahexwrench.

Readthissectioncompletelybeforeservicingthevessel.DONOTServiceanycomponentuntilyouverifythat

systempressureisfullyrelievedfromthevesselandthesystemiscompletelyshutdown.

WARNING


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4.2.5. Liftthelockingkitsegmentoutoftheretaininggrooveusingascrewdriver.Shouldthe

assembliesbedifficulttoremove,itmaybenecessarytorocktheheadslightlyortapthe

headinwardwitharubbermallet.Removetheendclosure.Itisrecommendedtouse

dedicatedendclosureremovaltoolsfromROPV.

4.2.6. RemovetheHeadAssemblywithOneoftheFollowingTechniques

4.2.6.1. ROPVHeadRemovalTool–AheadremovaltoolsetisavailablefromROPV.

Whilenotnecessaryforheadremoval,theyhaveprovenaneffectiveandeasyway

toremovethevesselheadwithoutcausinganydamagetothevessel.Therearefour

components:bearingblock,positionnut,bearingrod,centerpiece.

4.2.6.1.1. Threadthecenterpieceintothepermeateportoftheheadassembly,to

handtight.Donotovertightenthecenterpiece(Fig.2.3).4.2.6.1.2. Placethebearingblockattheendface.

4.2.6.1.3. Threadthepositionnutintothecenterpiece.

Figure2.2ROPVHeadRemovalTool

Figure2.1.


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4.2.6.1.4. Turnbearingrodclockwise.Theheadwillmovewiththebearingrodas

itmovestowardtheendofthevessel.Youwillbeabletoremovethehead

onceithasclearedtheretaininggrooveareaofthevessel.

4.2.6.2. AlternativeHeadRemoval–Itispossibletoremovetheheadassembly

withouttheROPVheadremovaltools.A1”NPTMalethreadedpieceofPVC(or

similarmaterial)pipeshouldbethreadedintotheheadpermeateporttohand

tightness.Pullthepipeoutwardtoremovethehead.Ifthevesselhasbeenin

operationforanextendedtime,aslightrockingmotionorforcefultugmaybe

requiredtobreaktheheadsealbond.Also,ahandleattheendofthepipewillease

headremoval–formingaTwiththepipethatthreadsintothepermeateport.

4.3. HeadDisassembling.

Readthisarticlecarefullybeforedisassemblingtheheadassemblytoprevent

damagingitscomponents.

4.3.1. Inspection:Makesurethattheendcapisremovedfromthevesselaccordingto

<OpeningtheVessel>

Figure2.5. Figure2.6.

Figure2.3. Figure2.4.


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4.3.2. Removetheadaptorandseals:Holdthebearingplatetightlywithonehandandpull

theadaptoroutofthepermeateportwiththeotherhand;removetheadaptorsealsand

thesealingplateseals.

4.3.3. Removethepermeateportlocknut:Removethelocknutusingadedicatedwrench.The

locknutislefthandthreadedandmustbeturnedclockwisetoberemoved.

4.3.4. Separatethebearingplateandsealingplate.Pullthesealingplatewithonehandto

separateitfromthebearingplate.

4.3.5. Separatedthepermeateport,andremovethefeed\concentrateport:pullthe

permeateportandfeed/concentrateportoutofthesealingplateandremovethe

retainingringofthefeed/concentrateport.

4.3.6. Removethesealsfromthesealingplateandpermport.

Figure2.9

Figure2.10

Figure2.7Removethelocknut Figure2.8Removesealingplate


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4.4. HeadAssemblyCleaningandInspection.Pleasereadthissectioncarefullybeforemakingdecisionsandtakingmeasureson

componentstructureorcorrosionproblems.Pleasecombinetheoperational

experiencewiththismanualtodealwithcorrosionandcomponentdamage.Youcan

referto<Breakdownsandsolutions>forthecontentthatisnotincludedinthissection

orcontactROPVforconditionsnotcoveredinthismanual.

4.4.1. CleaningandInspectionofthemetalliccomponents.

Metalliccomponentsincludethealuminumbearingplate,stainlesssteellockingkit

segmentsandscrews.

4.4.2. Inspectthecomponentsforscale,saltdepositorcorrosion;useasteelbrushora

scrubbingpadtoloosenanydeposit.Becarefulnottoscratchthebearingplate

anodizecoating.

4.4.3. Placethecomponentsintoavesselfilledwithmildsoapsolutionandremovethe

corrosion.

Carefully remove the seals to prevent damage to the sealing surfaces. It is recommended to replace all used

seals with brand new seals. NOTE

Figure2.11Headbreakdown

Components：sealingplate,adaptor，bearingplate,feed/concentrateport,retainingrings,

permeateportplug，permeateportlocknut，seals.


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4.4.4. Flushallcomponentswithcleanwater.

4.4.5. Drythecomponentswithcompressedairoracleananddrytowel.

4.4.6. Inspectallcomponentscarefully,checkforanystructuraldefectsordamageinthe

bearingplateanodizedcoating.Replaceanydamagedordefectivecomponent.

4.4.7. CleaningandInspectionofthenon‐metalliccomponents.Non‐metallic

componentsincludesealingplate,permeateport,adaptor,permeateportlocknut,

permeateportplugandallseals.

4.4.8. Inspectcomponentsforscale,corrosionorsaltdeposit.Placethecomponentsintoa

bucketfilledwithmildsoapsolutionandcleanthemtoremovethedeposits.

4.4.9. Flushallcomponentswithcleanwater.

4.4.10. Drythecomponentswithcompressedairoracleananddrytowel.

4.4.11. Inspectallcomponentscarefullyforanystructuraldefectsordamageintheseals.For

example,cracksinthepermeateportorthelocknut,damageinthethreads;aged,

deformedordamagedseals.Replaceanydamagedordefectivecomponentwithnew

ones.

4.4.12. Replaceallcomponentsthatneedtobechangeduponinspection.

4.4.13. InspectcarefullytheFeed/Concentrateportsandattachmentstotheshelltoensure

thatconnectionsandsealsarestructurallysound.PleasecontactROPVforany

questions.Pleasedonotconductanyrepairworkbeforeconsultingwiththe

manufacturerforguidance,exceptforreplacingheadcomponents.

4.5. HeadAssembly.

Readandfollowthissection.Incorrectassemblymayresultincatastrophicheadfailure.

If chemical reaction problems occur like cracks or discoloration on the vessel or its components, please contact please contact ROPV at: [email protected]

NOTE

We recommend using brand new seals for head assembly.

Lubricate seals using glycerin or silicone base lubricant.

ATTENTION


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4.5.1. Lubricateandinstalltheseals:

Lubricatethepermeateportsealsandplacetheminthegrooveslocatedontheinside

diameterofthepermeateport.Lubricatethepermeateportsealsandplaceitontothe

outeredgeofthepermeateport.

4.5.2. Lubricatethesealingplatesealsandplaceitinthegrooveslocatedontheinsidediameter

ofthesealingplate.

4.5.3. Lubricatetheadaptorsealsandplacetheminthegroovesoftheadaptor.

Figure2.13Installthepermeateportseals

Figure2.14Installthesealingplateseals

Figure2.15Adaptorsealsinstallation


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4.5.4. Assemblethesealingplateandbearingplate:

Applyathinlayeroflubricantontothesealingsurfaceofthefeed/concentrateportand

pushthefeed/concentrateportthroughtheholeofthesealingplate,thenfixitwith

retainingring.

4.5.5. Insertthelongerendofthefeed/concentrateportthroughtheholeofthebearingplate

untilfullcontactofthesealingplateandbearingplate.Thenapplyathinlayerof

lubricantontothesealsurfaceofthepermeateport,pushthepermeateportthroughthe

holeofthepartedsealingplatetothebottom.

4.5.6. Threadthepermeateportlocknutontothethreadsofthepermeateportusingawrench

untilthesealingplateandbearingplatearethoroughlycontacted.

Figure2.16Installingfeed/concentrateport

Figure2.16Assemblingsealplate Figure2.17Assemblingbearingplate

Figure2.18Installinglocknut 2.19Installingadaptor


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4.5.7. Installtheadaptor.Inserttheendwithoutsealsintotheholeofthepermeateport.

4.5.8. InstalltheheadO‐ring.LubricatetheO‐ringandseatitintothegroovelocatedonthe

outsidediameterofthesealingplate.

Figure2.20Headassembly


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Chapter5 Loading/ReplacingMembraneElementsReadallpartsofthissectionbeforereplacingmembraneelements.Thisarticleisforreference

only; load/unload the membrane elements according to the membrane manufacturer

requirements.

Membraneelementsmustbe loadedat the feed (upstream)endof thevessel,andunloaded

throughtheconcentrated(downstream)sideofthevessel.Alwaysremoveandinstallelements

inthedirectionoffeedflow.

Make amatching list for the removedmembrane and the vessel to avoid possible disorder

duringmembraneloading

Steps:

5.1. Inspection

5.1.1. Verifyallpressurehasbeenrelievedfromthevessel,followingsystemmanufacturer’s

recommendations.

5.1.2. EnsurethevesselisopenedaccordingtoOpeningtheVessel.

5.2. Disassemblemembranecomponents

5.2.1. Removethethrustringlocatedattheconcentrationside.

5.2.2. Removetheadapterfromthemembranesonbothsidesofthevessel.

5.3. Unloadthemembrane

5.3.1. Cleanoffanylubricantresidueorsaltbuildupfromtheinsidediameteratbothendsof

thevessel.

5.3.2. Remove the membrane out of the vessel according to the membrane manufacturer

requirements.

5.4. Checkandmakesure thehead isassembledaccording toHeadDisassemblyandHead

Assembly.

Be careful not to scratch the inner surface of the vessel while removing or installing the

membrane elements.

ATTENTION


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5.5. Vesselcleaningandinspection

5.5.1. Cleanthe innersurfaceandgrooveof thevesselbyremovingtheresidueorcorrosions

withamildsoapsolutionandthenflushwithcleanwater.

5.5.2. Checkifthereisanydamagetotheinnersurfaceofthevessel.Ifyes,Pleasechangethe

vessel.

5.6. Installtheheadattheconcentrationside

5.6.1. Applyathinlayerofglycerinwithin50mmfromthegrooveontheinnersurfaceofthe

vesselattheconcentrate(downstream)endofthevessel.

5.6.2. Apply a thin layer of glycerin on the surface of the head O‐ring for the concentrate

(downstream)endofthevessel.

5.6.3. Installthethrustringontotheheadfortheconcentrate(downstream)endofthevessel.

5.6.4. Graspthepermeateportandthelocknuttokeeptheheadandthevesselinthesameaxis

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. Pleasedonot

push the head toomuch over the groove since the sealsmay be damaged if the head

needstobepulledback.Ifitisdifficulttopushtheheadwithhands,arubbermalletcan

beusedtohittheheaduntiltheheadreachesitsplace.

Figure2.22Installthethrustring

Figure2.21Inspectingthevessel


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5.7. Installlockingkitsegmentatconcentrationside.

5.7.1. Inspectthegrooveandensureitiscleanandfreeofresidues.Usecompressedairtodry

thegrooveifavailableoruseacleanragtodryit.

5.7.2. Applylubricantlikeglycerinontothelockingkitsegmentscrewstopreventsaltdeposits

tobuildup.Positionthe lockingkitsegments intothegroove. Install thescrews, tighten

screwsupto10Nmoftorque.

5.8. Loadmembraneelementsfromthefeedendofthevessel

5.8.1. Inspectandconfirmtherearenoscratchesontheinnersurfaceofthevessel.

5.8.2. Inspect and ensure there is nothing on the outer surface of the membrane that may

scratchtheinnersurfaceofthevessel.

5.8.3. Usingacleanragorcottonandamixtureofglycerinandcleanwaterata1:1ratioball

lubricatetheinnersurfaceofthevessel.

5.8.4. Usingacleanragorcottonandamixtureofglycerinandcleanwaterata1:1ratioball

lubricatethemembraneseal.

5.8.5. Load the membrane from the feed end of the vessel; ensure that the membrane is

properlyorientated.Iftherearemorethanonemembranetobeloadedintothevessel,do

notpush the firstmembrane into the vessel completelybut reserve around200mm to

facilitatetheconnectionofthenextmembrane.

5.8.6. Inspect andmake sure themembrane interconnector is clean and intact. Apply a thin

layerofglycerinontotheinterconnectorsealswithoutexcessiveamount;otherwisethe

membranemaygetcontaminated.Installtheinterconnectorintotheloadedmembrane.

5.8.7. Installandconnectthenextmembranewiththeloadedonewiththeinterconnector.

Figure2.23Installlockingkitsegment


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5.8.8. Loadallmembraneelements in the sameway. Pushall themembranes into the vessel

until the adaptor at the concentration end is inserted into the center hole of the first

membraneandthemembranefaceispushedagainstthethrustring.

Please ensure all membranes are in the same axis. No load on the connection pipe, otherwise the

pipe or the membrane may be damaged.

ATENTION


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Chapter6 ClosingtheVesselPleasereadthisarticlecarefully.Incorrectassemblymayresultincatastrophicfailure.

6.1. Pre‐ClosingInspection

6.1.1. InspecttheheadisassembledasperHeadDisassemblyandHeadAssembly

6.1.2. VerifythatthemembranesareloadedasperLoading/ReplacingMembraneElements

6.1.3. Ensuretheinnersurfaceofthevessel isfreeofcorrosionbuilduporresidueof foreign

materials.

6.1.4. Inspectandmakesuretherearenoscratchesordamageontheinnersurfaceofthevessel.

6.1.5. Inspectthevesselgrooveandmakesuretherearenoresiduesorsaltbuildupinit.

6.1.6. InspecttheFeed/Concentrateportconnectionsandvessel,makesurethesealsareintact,

structurally soundand freeofcorrosion. Ifyouhaveanyquestionsor findanyadverse

situationpleasecontactROPV.

6.1.7. Shimming themembranes.Due to variationon the length of themembranes and the

vesseltolerance,shimmingmightbenecessarytopreventmembranemovementduring

operation.

6.1.7.1. Remove the adaptor seals and the headO‐ring. Insert the straight end of the

adaptorintothepermeatehubfarenoughtobeheldbytheadaptorseal.Alignthe

adaptorwith themembrane andpush the head carefully into the vessel until the

grooveisexposedfarenoughtoinsertalockingsegmentintoit.Slowlyremovethe

head with care and then check the size of the gap between permeate port and

adaptor.Thenumberof2mmshimsneededtofillthisgapwilldependonthesizeof

thegap.Reinstalltheadaptorsealsandsealplateseal;slideshimsontheflatendof

the adaptor and insert the adaptor into the permeate port hub. Shims must be

placedbetweenthepermeateportandadaptor.

6.2. Installheadatthefeedend(upstream)

6.2.1. Applyathinlayerofglycerinwithin50mmfromthegrooveontheinnersurfaceofthe

vessel.

6.2.2. ApplyathinlayerofglycerinontotheheadO‐ringatfeedend.

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.

Warning


- 23 -

6.2.3. Grasp thepermeateport and locknut; keepheadandvessel in the sameaxis.Push the

headintothevesseluntilsomeresistancecanbefelt.Pushtheheadslowlyintothevessel

untilitreachesoverthegroove.Pleasedonotpushtheheadtoomuchoverthegroove

sincethesealsmaybedamagediftheheadneedstobepulledback.Ifitisdifficulttopush

theheadwithhands,arubbermalletcanbeusedtohittheheaduntiltheheadreachesits

place.

6.3. Installlockingkitsegmentatfeedend

6.3.1. Inspectthegrooveandensureitiscleanandfreeofresidues.Usecompressedairtodry

thegrooveifavailableoruseacleanragtodryit.

6.3.2. Applylubricantlikeglycerinontothelockingkitsegmentscrewstopreventsaltdeposits

tobuildup.Positionthelockingkitsegmentsintothegroove.

6.4. Installthepermeateportplug.

ApplyTeflonsealingtapeonthethreadsoftheplug,notexceeding2layers,beforethreading

it into the perm port. Over tighteningmay damage the permeate port.Maximum torque is

15Nm.Tightenplugat50%ofthemaximumtorque.Theendfaceoftheplugshouldbe3mm

higherthanthepermeateportface.

6.5. Reconnectthepipes

ReconnectthepipesasperPipingConnections.

6.6. CheckasperAppendixIPre‐RunningCheckList

Figure2.24Installpermeateportplug


- 24 -

Chapter7 HandlingandStorageRead this article carefully. Incorrect handling and storagemay result in catastrophic

failure.

Checkthepackingconditionswhenacceptingthegoods.Contactthelogisticscompanyat

onceincaseofdamagedvessel.

Slightdamage in theoutersurfaceof thevesselwithin thepainting layer isacceptable.

Anyquery,pleasecontactROPV.

7.1. VesselHandlingPrecautions

Keepthevesselfromfallingdowntothegroundorcollidingwithotherobjectswhenitisbeingmoved.

Specialcareshouldbetakenifforkliftorothermachineryisusedforhandlingthevessel.

Usepaddingtoprotectthevesselsduringhandlingtopreventdamage.

DONOTScratchordamagetotheinnersurfaceofthevessel.

DONOTliftthevesselfromtheFeed/Concentrateportsorpermeateports.

DONOTimposeexcessiveexternalforceonthevessel.

DONOTclimbonthevessel.

Damagedvesselmustnotbeused.

7.2. StorageRequirements

Donotstorewithotherproducts.

Makealistofproductandsparepartsbeforestorage.

Storevesselsintheiroriginalpackaging.

Storagetemperaturerangeshouldbe‐10ºC~+50ºC Storagehumidityrangeshouldbe40%~70%RH；

Storeinaplacewithalightintensityoflessthan100Lux；

Storeinasafeareatokeepthevesselfromshakingorfalling.

Height:notexceeding3packingunits.


- 25 -

Figure2.27Storageprocedure

Checking

Checkstorageconditions

Checkheight

Finishthestorage

Checkingpackaging

Productquantity

Partsquantity

Temp.‐10ºC~+50 ºC

Humidi40%~70%RH

Lightlessthan100Lux

Safestoragearea


- 26 -

Chapter8 BreakdownsandSolutionsPleaserefertothisarticleforcommonbreakdownsandsolutions.Thecontentsofthissection

needtobeusedwithgoodpracticalindustrialexperience.Werecommendthatonlyengineers

withextensiveworkexperienceconductanyrepairwork.

8.1. LockingKitSegmentandRelatedIssues.

8.1.1. Lockingkitsegmentscrewistootighttothreadout.

Solution:Applypenetrating fluid (suchasWD‐40orLPS‐1)onto the lockingkit segment

and tap it with a hammer until the screw can be threaded off. Please take care not to

contaminatethemembraneelements.

8.1.2. Lockingkitsegmentscrewcannotberemovedduetodamageinscrewcaporthreads

Solution:cutthelockingkitsegmentscrewoff.

Tools:anglegrinder,cuttingdisc,powercables,electricdrill,M8screwtap,6mmstainless

steeldrillbit.

Steps:

‐Cutthelockingkitsegmentscrewwithanglegrinder

‐Useanelectricdrillwithstainlesssteelbitwithdiameterof6mmtodrilltherestofthe

screwoutofthebearingplate.Pleasetakecarenottodamagethethreadsofthescrewhole

inthebearingplate.

‐MakenewthreadsforthescrewholeinthebearingplatewithaM8screwtap.

‐Flushtheresiduewithcleanwater.

8.2. HeadandRelatedIssues.

8.2.1. Leakageinseals

Possibilities:

A.Deterioratedheadsealsafterrunningforover2years

B.Sealsaredamagedduetoimproperinstallation

C.SealsaredeformedduetothePHofthemedium

D.Sealsaredeformedduetothetemperatureofthemedium

Solution：

a.Checkthecomposition,temperature,andPHofthemedium.

Take care not to damage bearing plate, vessel and permeate port during cutting. Helmet and mask must be used for protection.

ATENTION


- 27 -

b.ReplacethesealsasperMaintenanceGuide.

8.2.2. Sealingplateorpermeateportisdamaged.

Solution:Replacesealingplateorpermeateport

8.2.3. Bearingplateiscorrodedduetoleakageinvessel

Solution:RepairtheleakageandreplacebearingplateasperVesselandRelatedIssues.

8.3. VesselandRelatedIssues.

8.2.4. Leakageinsealingsurfaces.

Possiblereasons:

‐ Scratchesordamagedboreatthesealarealocation.

Solution:Forlitescratches,handsandsealingareasusingwet600gritsandpaperuntilasmooth

finishisachieved.Fordipdamageorscratchesnotaffectingthestructuralwall(.2mm),epoxyor

vinylesterresincanbeusedtofillthedamagedsurface.

8.2.5. Vesseliscorrodedorcracked

Possiblereasons:

A. Phoutofrange,mediumistoacidoralkaline.

B.Non‐acidmembraneshellsmixedwithacid‐proofmembraneshell.

Solution：

a． Inspectthecracks:

Ifitisahighpressurevesselorthecracksreachstructurallayer(.2mmdeep),thevesselmustbe

replaced.

b． Checkthemedium:

CheckthePHrangeandadjustaccordingly.

8.2.6. Bodydamage.

A.Duringtransportation

B.Duringinstallation

Solution: replace the vessel if the body is seriouslydamaged;measuresbelow canbe taken if

thereisonlyslightdamage

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.

ATENTION


- 28 -

Tools:paintinggun,aircompressor,electricdryer,angelsanderandsandingdisc,louverblade.

Materials:Epoxyresinandhardener,bodyfillerandhardener,ROPVpaint,fiberglassmat.

Steps:First,useepoxyresin,mats,fiberglassmattofillthedamage,oncetheresiniscuredsand

theexcessuntilthesurfaceislevelandsmooth;applybodyfillerifnecessary;last,paintwitha

paintinggun.

8.4. Feed/ConcentrateSidePortsandRelatedIssues.

PleasefollowstepsbelowtoremoveFeed/Concentratesideportsincaseofleakage.

A． Shutdownthesystemanddrainthevessel.

B． DisconnectthepipingoffthepermeateportandFeed/Concentrateports.

C． OpenthevesselasperOpeningtheVessel.

Possiblereasons:

1．Sealsaredamaged

Solution:replacetheseals

2．Portsarecorrodedordamagedorthesealinggrooveisscratched.

Solution:replacetheFeed/Concentrateports

3．Portsandthemanifoldsarenotinthesameaxis(misaligned)

Solution:adjustthemanifoldsandreconnectthepipesasperPipingConnections.

8.5. LowPermeateWaterQuality

Possiblereasons:

A.O‐ringsealsaredamageddue todisplacedmembraneelementscausedby frequentstarting

andshuttingdownofthesystemwithouttakingmeasurestoensuregradualpressureincrease

whenstartingandgradualpressurereleasewhenshuttingdown.

Solution：

a.RemovetheheadasperOpeningtheVesselandremovetheadaptor.

b.Replacethepermeateportsealsandadaptorseals.

c.ClosethevesselasperLoading/ReplacingMembraneElementsandClosingthevessel.

For any leakage of Feed/Concentrate port, please contact

Harbin ROPV Industry Development Center

ATENTION


- 29 -

B.Membranesmaybedisplacedoutof thesealingareaduringstartingandshuttingdownthe

system.

Solution:Shimmingthemembranes.

a.RemovetheheadatfeedendandadaptorasperOpeningthevessel.

b.RemovetheadaptorsealsandtheheadO‐ring.Insertthestraightendoftheadaptorintothe

permeatehubfarenoughtobeheldbytheadaptorsea.Aligntheadaptorwiththemembrane

andpush thehead carefully into the vessel until the groove is exposed far enough to insert a

locking segment into it. Slowly remove theheadwith 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

dependonthesizeofthegap.Reinstalltheadaptorsealsandsealplateseal;slideshimsonthe

flatendoftheadaptorandinserttheadaptorintothepermeateporthub.Shimsmustbeplaced

betweenthepermeateportandadaptor.

c.ClosethevesselasperClosingtheVessel.


- 30 -

Chapter9 ServiceguideDearusers：

Thanks for choosing ROPV FRP pressure vessels. We provide you with thefollowingservicesaccording toournational lawsandregulations (SeeROPVLimitedWarrantyformoredetails):

I．Qualitywarranty

ROPV promises to provide “one‐yearwarranty and lifetimemaintenance” on the conditionthatthevesselsareproperlyinstalledandoperated.

II．Technicalsuppport

1．ROPVcommitstoreplyuserswithin8hoursfortheircomplainortechnicalconsultation.

2．ROPVcommitstoarriveatprojectsitewithin48hoursifneeded.

III．Exclussionsforthefreeservicecoverage

1．Damagescausedbyimpropertransportation,installation,operationandmaintenance

2．Damagescausedbyoperationwithoutstickingtotherequirementsinthismanual

3．InvoicesarealteredorInspectionCertificateisnotavailable

Phone：0451‐82267301/02/06/08

E‐mail: [email protected]

Website：www.ropv.com.cn

Any problem, please contact via after-sales hotline 0451-82267309

TIP:


- 31 -

AppendixIPre‐RunningCheckList

Name DrawingNo.

Pressurerating VesselNo.

Items Status

Membraneelements

Membraneisloadedasperrequirements YES□NO□

Adaptorisinstalledasperrequirements YES□NO□

Thrustringisinstalledasperrequirements YES□NO□

Vessel

Allcomponentsarecleanandingoodconditions YES□NO□

Vesselisinstalledandfixedasperrequirements YES□NO□

Headisassembledasperrequirements YES□NO□

Locking kit segment and securing ring (highpressurevessels)areinstalledasperrequirements

YES□NO□

Thepressuregageofclosedvesselreadsthesameasthatofthesystem

YES□NO□

Pipingconnections

Pipes are connected as per requirements withoutstressconcentration

YES□NO□

Allpipingcomponentsareingoodconditions YES□NO□

Installationstaff: Installationdate:

Inspector: Inspectiondate:


- 32 -

AppendixIIMaintenanceCheckList

Name VesselNo.

Pressurerating Workpressure

Runningtime Timesofmaintenance

Item Status Treatment

Corrosion YES□NO□

Deterioration YES□NO□

Damage YES□NO□

Leakage YES□NO□

Inspector： Inspectiondate：

Maintenancestaff： Maintenancedate：


- 33 -

ROPVLimitedWarrantyHarbin ROPV Industry Development Center (hereinafter called “ROPV”) vessels (the “Product”) arewarranted to the original purchaser (the “Customer”) under normal use and if installed, operated andmaintained in accordance with applicable User Guides to be free of defects in material and/orworkmanship for a period of one (1) year from date of manufacture subject to the following. AnyreplacementProductorPartwillbewarrantedonlyfortheremainderoftheoriginalwarrantyperiodorthirty(30)days,whicheverislonger.

ExclusionsfromthisLimitedWarranty

Thewarrantyshallbevoidif:

1. Defectsarenotreportedduringthewarrantyperiod.2. The Product is subject to accident, damage, incorrect installation, mishandling, abuse, misuse,

negligenceoraccidentbyanyotherparty.3. Problemscausedbymodificationoralteration.4. Chemicalexposureoractsofnature.5. Anyitemmanufacturedbyothercompanies.6. Wearonreplaceablecomponentsundernormalconditions–sealsareexcludedfromthiswarranty.

ProcedureforObtainingWarrantyPerformanceROPVreservestherighttodetermineifareporteddefectisabreachofthiswarranty.Thismayrequire,at ROPV’s discretion, one ormore of the following: 1. an inspection or test of the Product and/or thesysteminwhich itwas installedbyanROPVrepresentative‐thecustomer isresponsible forarrangingaccesstotheProduct.2.aninspectionortestoftheproductand/orthesysteminwhichitwasinstalledbytheCustomer.3.an inspectionortestof theproductand/orthesysteminwhich itwas installedbythird party inspector appointed byROPV. 4. return of the Product toROPV’s factory for inspection ortesting.This isnotastatementof limitations forwarrantyperformanceandROPVreservestherighttoconductwarrantyperformanceoutsideoftheitemsshown.IftheProductisfoundbyROPVtobedefectiveunderthetermsofthiswarranty,ROPVwillperformoneof the following at its option: 1. supply a substantially similar replacement part based on FOB factoryterms.2.conductafieldrepairoftheProduct.3.issueacreditfortheoriginalcostoftheProducts.ThisisnotastatementoflimitationsforwarrantyperformanceandROPVreservestherighttoconductwarrantyperformanceoutsideoftheitemsshown.ProductsreturnedtoROPVfor inspectionor testingmustbeshippedfreightprepaidat theCustomer’sexpense. If a breach of warranty is confirmed, ROPVwill bear all costs related to the inspection andtesting. If the Product failure is found to be caused by cause other than breach of warranty, all costsrelated to the inspection and testing of the Product will be borne by the Customer. This includes aUSD$500perdayfeeandallrelatedtravelexpenses.AllreporteddefectsmustbesubmittedtoROPVinwriting.

DisclaimerROPVmakes no expressed or implied warranty other than that specifically set forth in this warrantystatement.ROPVdisclaimsanywarrantyofmerchantabilityoroffitnessforaparticularpurpose.ROPV’sliabilityunderthetermsofthiswarrantyshallnotexceedthepurchasepriceoftheProductwhichare claimed to be defective. ROPV shall not be liable for any consequential or incidental damageswhatsoever, including but not limited to injuries or damages to person or property, loss of businessprofits, business interruption, loss of use, cost of removing/installing Products, or the claims of thirdparties.

WarrantiesorRepresentationsbyOthersNoagent,employee,dealer,orotherpersonhasanyauthoritytomakeanywarrantiesorrepresentationsconcerningROPVortheProduct.ROPVisnotresponsibleforsuchclaimsofwarrantyorrepresentation.

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