User's Guide 9to: - Phoenix Vessel Technology Ltd.
Contents
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6. Length Up to 300 of membrane elements Working Fluid Water brackish Design Pressure 1000 1200 psi Test Pressure 1 1 times design pressure for upto 15 minutes maximum Design Temperature 20 to 113 F 7 to 459 Expansion 0 5 to 0 6 mm per metre length of vessel at design pressure Vacuum condition Down to 14 5 psi 0 bar absolute Support Position 2 supports for 1 to 4 5 407 elements supports for 5 to 7 5 407 elements and any length supported outside of the recommended support range refer to Vessel Support Position Section 2 2 this User s Guide NOTE The standard materials of construction may not be compatible with cleaning and preserving fluids See Section 3 4 for further information If in doubt submit request to Phoenix Vessel Technology Limited NOTE The vessel should not be allowed to freeze solid This will damage the vessel wall and make replacement necessary 22 of 31 USER GUIDE MAY 2012 phoenix 3 3 SAFETY PRECAUTIONS Fibreglass reinforced pressure vessels will provide years of safe service if properly installed and maintained This section is for guidance only and should be used in conjunction with the recommendations in the previous sections Attention is drawn to the located at the bot tom of the page which highlight potential problems areas and safety recommendations 3 3 1 Provide pressure relief device This should be set to no more than 105 of de
7. gap between two segments is greatest It may be of assistance to tap the End Cap with a soft mallet shaft to free the segments 4 of 31 USER GUIDE MAY 2012 phoenix 1 1 5 A soft mallet is a useful tool for removing and inserting the end fittings however it should be used with discretion and have the following specification NOTE A metal headed hammer is not recommended for use with these pressure vessels 1 1 6 To remove the End Cap requires an extractor There are two designs available The lowest cost version exerts pull load onto the product connection thread the alternative design which is more universal takes longer to assemble onto the end cap but has a greater pull load consists of two tripods and 3 long cap head screws M10x1 5 these screwed into the securing screw threads of the End Cap Extraction load is applied via the large threaded bolt at the centre axis Both types are illustrated below 5 of 31 USER GUIDE MAY 2012 phoenix 1 2 DISASSEMBLING END CAP 1 2 1 With the End Cap extracted Unscrew the Backnut located on the Product Tube Grasp the Product Tube and unscrew it from the End Cap approximately 2 turns until a gap of 5 to 10 mm appears 1 2 2 Push the Product Tube back into the End Cap and at the same time pull out the black coloured Collet at the other end of the Product Tube The 5 to 10 mm gap should now appear on the other side of the end cap 1 2 3 Using a small
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11. el at design pressure Victaulic clamps used for connection to vessel should be assembled tightly with bolt pads of clamp halves metal to metal It is recommended that two Victaulic couplings are used to connect the vessel to the mani fold ie there is an intermediate pipe section between vesssel and manifold which can take up vessel or manifold movement This intermediate pipe section should be at least 4 in length The vessel thermal expansion is typically 25 x 10 exp 6 per C in the length direc tion NOTE Excessive torque applied to the straps may damage the vessel wall and cause the strap nut to seize onto the threaded portion phoenix SECTION THREE OPERATION 3 1 CORROSION Operational pH level 3 10 Cleaning only pH level 2 12 for no longer than 30 mins Imediately clean down amp purge Whilst every effort has been taken to ensure that end fittings have adequate corrosion resistance it is the responsibility of the purchaser to assess that the materials offered are suitable for the spe cific corrosion environment Alternate materials are available with enhanced corrosion resistance contact Phoenix Vessel Technology Limited for advice End fittings should be maintained dry and free from corrosion Vessel leaks should be investigated and corrected 21 of 31 USER GUIDE MAY 2012 phoenix 3 2 OPERATING CONDITIONS DESIGN SPECIFICATION Internal Diameter To fit any 8 nominal diameter element
12. ented Retaining Rings then the elements have been pushed too far during loading Remove the last element by pushing it through the vessel taking to support its weight as it emerges Refer to Section 1 4 Loading Membrane Elements for further information 1 5 4 With the end cap in place insert one of the three Segmented Retaining Rings and fix with one of the three Cap Head Screws Do not tighten yet leave loose as this will make for easier location of the remaining Segmented Retaining Rings Put the remaining Segmented Retaining Rings into position before inserting the Cap Head Screws Finally tighten hand tight up to a maximum torque of 8 8NM TORQUE NOTE Remember to refit all O Seals Thrust Ring and insert Adaptors into the central core tube of the first and last element in the stack NOTE A partially or badly assembled pressure vessel is dangerous Carry out visual inspection on vessel to check compliance with these instructions Check working area for any items left unassembled 17 of 31 USER GUIDE MAY 2012 phoenix 2 1 2 1 1 SECTION TWO INSTALLATION HANDLING Vessels may be stored horizontally in any warehouse where the temperatures are as follows Maximum 459 113 F Minimum 09 32 F DO NOT subject the vessel to sharp blows or impacts as this may damage the vessel wall DO NOT use the ports which project beyond the vessel as lifting or manoeuvring aids DO NOT scratch the ve
13. hich adheres to the vessel may be removed by lightly polishing the area with waterproof silicone carbide paper Use 400 Grade fine to start with and finish with 600 Grade very fine It will help to moisten the grit paper with water during use Avoid continuously rubbing the same spot in the same direction Afterwards remove any debris with water or by using a clean cloth b that there no sharp edges to the membrane element which could scratch the vessel Contact the element manufacturer if these cannot be easily removed Check the element brine seal for wear and or cuts Consult the element manufacturer for Spares and advice NOTE Sharp debris may scratch vessel bore This should be removed before unloading elements NOTE Fine grade Scotchbrite may be substituted for waterproof silicone carbide paper 1 4 3 LOADING MEMBRANE ELEMENTS a Lubricate the inside of the vessel with glycerine If this is not available then flood vessel with clean water b Check with the element manufacturer concerning the position of the brine seal Normally this is placed on the upstream end of the element with the recessed part of the seal pointing upstream Push the elements into the vessel from the upstream end 12 of 31 USER GUIDE MAY 2012 9 f h As each element is loaded insert the interconnector To ease insertion glycerine should be applied to the O seals Care should be taken to en
14. n any two vessels loaded with elements due to tolerance build up each will require measuring to find the exact number The ideal situation is to have a working float of 5 10 mm at the upstream end of the vessel to allow for future thermal expansion and contraction The best method of achieving this is to fit the maximum number of Shims 8 at 5mm thickness and to keep subtracting Shims one at a time until the Segmented Retaining Ring fits into the groove in the vessel Finally subtract one more Shim to ensure a safe float of 5 10 mm i Normally only one Thrust Ring is provided per vessel the correct location being at the downstream end of the vessel The design of Adaptor and Thrust Ring ensures even loading over the face of the element phoenix NOTE NOTE NOTE Incorrect location of the thrust ring will damage the membrane elements Please ensure the holes in the thrust ring are aligned with the ports in the vessel Please ensure plastic screws in thrust ring are tightened sufficiently to avoid movement during operation 15 of 31 USER GUIDE MAY 2012 1 5 CLOSING VESSEL 1 5 1 Check the inside of the vessel for debris which may scratch the vessel Remove any that is found by flushing with water or by using a clean cloth Stubborn debris which adheres to the vessel may be removed by lightly polishing the area with waterproof silicone carbide paper Use 400 Grade fine to start with and finish with 600 Grade ve
15. or reverse osmosis membrane elements It is one of a small number of companies with Code X accreditation of the American Society of Mechanical Engineers Vessels are produced to cover a range of pressures upto 1200 psi and to house seven 40 or five 60 membrane elements Each vessel has a documented history in terms of the manufacturing process and the materials used Before despatch each vessel is tested to 1 1 times working pressure to ensure structural integrity This User s Guide applies to the 8 side ported pressure vessel 1000 or 1200psi which is currently available with 1 5 2 2 Victaulic feed and concentrate ports The permeate connection can be 1 BSP Female The following Assembly Drawings are applicable 1 3639 1 5 2 0 1000 Psi 2 3643 2 5 3 0 1000 Psi 3 2101 1 5 2 0 1200 Psi 4 3624 2 5 1200 Psi 5 3333 3 0 1200 Psi 3 of 31 USER GUIDE MAY 2012 phoenix SECTION ONE MAINTENANCE GUIDE 1 1 REMOVING END CAP FROM VESSEL 1 1 1 Ensure system is NOT pressurised before starting work 1 1 2 Remove connections if fitted from the central product port 1 1 3 Using an 8mm A Flats hexagonal T bar or Allen key remove the Cap Head Screws located in recesses in the Retaining Rings 1 1 4 Remove the 3 segments of the Retaining Ring Each segment has a slot at one end to enable it to be levered out If removal is difficult then start at the point where the
16. phoenix vessel technology ltd User s Guide to Phoenix Vessel Technology Limited 400 1 200 psi Side port pressure vessels 1 5 2 0 2 5 3 0 Model numbers 3314 3341 3639 3643 2101 3642 3333 2058 3601 3602 2059 3600 Phoenix Vessel Technology Limited Unit 2 The Old Bakery Lower Tuffley Lane Gloucester GL2 5DP T 44 0 1452 311673 E info phoenixvessel co uk F 44 0 1452 310295 www phoenixvessel co uk phoenix TABLE OF CONTENTS Page No FORWARD 3 SECTION 1 Maintenance Guide 5 11 Removing End Cap from Vessel 5 1 2 Component Disassemby 1 3 Component Assembly 10 1 4 Loading Membranes 12 1 5 Closing Vessel 16 SECTION 2 Installation 18 2 1 Handling 18 2 2 Vessel Support Position 19 2 3 Connections to Vessel 20 SECTION 3 Operation 21 3 1 Corrosion 21 3 2 Operating Conditions 22 3 3 Safety Precautions 23 SECTION 4 Appendix 24 4 1 Spare Parts List 24 4 2 Assembly Drawing 3314 1 572 07 1000 Psi 25 4 3 Assembly Drawing 3341 2 5 1000 Psi 26 4 4 Assembly Drawing 3639 1 5 2 0 1000 Psi 27 4 5 Assembly Drawing 3643 2 5 3 0 1000 Psi 28 46 Assembly Drawing 2101 1 5 2 0 1200 Psi 29 4 7 Assembly Drawing 3624 2 5 76mm 1200 Psi 30 4 8 Assembly Drawing 3333 3 0 1200 Psi 31 2 of 31 USER GUIDE MAY 2012 phoenix FORWARD Phoenix Vessel Technology is a major manufacturer of Glass Reinforced Plastic Pressure Vessels which are used as housings f
17. ry fine It will help to moisten the grit paper with water during use Avoid continiously rubbing the same spot in the same direction Afterwards remove any debris with water or by using a clean cloth 1 5 2 Lubricate the vessel inside surfaces with glycerine 1 5 3 Lubricate the assembled cap with glycerine particularly the large 8 diameter O seal 1 5 3 1 Insert the end cap squarely into the Vessel Body sufficient to allow the Segmented Retaining Rings to be inserted fully into the groove in the end of the vessel If the end cap is difficult to push into the vessel then use the shaft of a soft mallet of appropriate type see Section 1 1 to tap it into position NOTE If the end fitting is inserted at an angle ie not squarely then there is a risk that the large end plate seal may come off resulting in seal damage and leaks on start up NOTE Fine grade Scotchbrite may be substituted for waterproof silicone carbide paper NOTE Do not use excessive force to insert the end cap A light tap is sufficient phoenix 1 5 4 Ifthe cap cannot be easily inserted then the following checks should be carried out i Lubricate vessel surfaces with more glycerine and try again ii The elements may have been pushed too far proceed as follows Remove large 8 diameter O Seal from end cap iii Without the large O Seal no effort should be required to insert the end cap if there is still insufficient space to insert the Segm
18. screwdriver prise open the Collet by pushing the blade of the screwdriver into the gap This should enable the Product Tube to release cleanly and preserve the threaded portion of it for re use later 6 of 31 USER GUIDE MAY 2012 1 2 3 To remove the Feed Concentrate Port first remove the Port Clamp and Clip Push the port into the vessel upto the shoulder of the Victaulic groove phoenix OMPONENT A VIBLY 1 3 1 Thoroughly clean all parts and check for the following a O Seals cracked worn or cut areas Feed Concentrate Port bent or distorted corroded Backing Plate dented anodising or locating threads for cap head screws damaged d _ Segmented Retaining Ring bent or distorted Head Screws bent corroded or threads damaged f Product Tube threads damaged or sealing areas scratched g End Plate cracks or scratches in sealing areas h Adaptor cracks or scratches in sealing areas Anti Rotation Collet cracked or broken Backnut cracked broken or thread damaged gt gt Components which show any of the above should be replaced 1 3 2 CORROSION Examine metal components for evidence of corrosion which might affect structural performance Particularly pay attention to the Backing Plate and Segmented Retaining Ring set The Backing Plate may be cleaned using fine grade waterproof silicone carbide paper 600 grade or finer Components which canno
19. sign pressure 3 3 2 Before pressurisation visually check that the segmented retaining rings are in position and secured by the three cap head screws and that the backnut is fitted and is screwed up tightly 3 3 3 DO NOT stand in line of end fitting while pressurisation takes place 23 of 31 USER GUIDE MAY 2012 phoenix SECTION FOUR APPENDIX 4 1 SPARE PARTS LIST For part numbers and descriptions please refer to the relevant Technical Information Sheet 24 of 31 USER GUIDE MAY 2012 ET AW SOW ddd O SLIT u 1304 305 158 0001 13553 55 8 Cie HPE METE GS 1 Shy COSC Lots Ma eae NOD mow EWI 5 aed i ET AT i dW D Ta TAAN MEAL AAA PLEIN CE EHS k F ASSY ONES 167 11 858 5 21 WES OTH 1 ONS 725 0 1 daa 4 2 ON ee 0 91 Hoor 21 Was Fi SAAS SSNS rn 17
20. ssel inside wall Slings wrapped around the vessel wall and suspended from the forks of a fork lift truck are safer and more stable than using forks alone Forks should always be padded before being brought into contact with any part of the vessel body VESSEL DAMAGE This should be reported to the shipping company and Phoenix Vessel Technology Limited 18 of 31 USER GUIDE MAY 2012 phoenix 2 2 VESSEL SUPPORT POSITION The bending stresses generated in a long pressure vessel can be considerable and should not be ignored Careful choice of support position can minimise bending stresses to an acceptably low level Always follow instructions stated on the Assembly Drawing for each particular vessel design and length ordered No of 40 No of Distance rtween Distance between Outer Elements Supports Supports mm Supports mm __ Mn __ _ _ 50 _ 50 860 3875 2480 support 19 of 31 USER GUIDE MAY 2012 2 3 CONNECTIONS TO VESSEL 2 3 1 2 3 2 2 3 3 2 3 4 2 3 5 Mount vessels using support saddles provided on horizontal surface at the recommended support position and tighten straps to eliminate movement do not tighten to more than drawing recommended torque Provide pressure relief device This should be set to no more than 105 of design pres sure Allow for an expansion of 0 5mm per metre length of vess
21. sure that the weight of the element is not taken on the interconnectors during loading The final element should be inserted the following distances in from the end of the vessel Vessel Type Element Insertion Distance MIN MAX 8 1000 psi Side Port 297 8 1200 psi Side Port 290mm 305mm If the elements are pushed too far then continue pushing until the first element emerges from the other end of the vessel Take care to support its weight as it emerges Fit the adaptors provided with the vessel end cap to the core tube of the elements at both ends Shims may required to ensure that element remains connected to the pressure vessel end fitting These must be placed between the Adaptor and the Product Tube at the upstream end only i e at the opposite end to the Thrust Ring The Shim 15 a solid plastic washer OD 55mm ID 33mm by 5 mm thick A maximum of 8 at the upstream end of the vessel may be used MAXIMUM OF 8 UPSTREAM END OF VESSEL ONLY SHIM WIDTH 5MM NOTE Shims reduce wear on O Seals by controlling the amount of free movement available to the element stack They can be fitted on all element types but are only supplied for spigotted element applications NOTE Adaptors must be fitted to both ends of the stack of elements Catastrophic failure of the product line can occur if adaptors are not fitted and pressure is applied The required number of Shims may vary betwee
22. t be restored to the as new condition should be replaced NOTE It is recommended that O seals are replaced every time the end 15 rebuilt NOTE Damage to anodising may be temporarily repaired by sealing with epoxy paint 1 3 3 Assemble the End Plate with its O seals 9 31 gt D 2012 phoenix 1 3 4 Assemble the End Cap as illustrated NOTE Lubricate the O Seals with Glycerine Do not use grease as this may impair the performance of the membrane elements 10 of 31 USER GUIDE MAY 2012 phoenix 1 3 5 Ifthe Side Port was removed earlier then assembly is the reverse of disassembly see previous section However once the seal has been fitted to the porta locating jack is required to engage the seal on its seat NEW PICTURES REQUAIRED 11 of 31 USER GUIDE MAY 2012 phoenix 1 4 LOADING MEMBRANES This Section is provided as a Guide only reference should be made to the element manufacturers recommendations for loading 1 4 1 UNLOADING MEMBRANE ELEMENTS a Ensure system is NOT pressurised before starting work b Remove both end caps from vessel c Remove thrust ring and adaptors from vessel d Remove element from vessel following element manufacturers recommendations 1 4 2 CHECKS BEFORE LOADING a Check the inside of the vessel for debris which may scratch the vessel Remove any that is found by flushing with water or by using a clean cloth Stubborn debris w
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