User's Guide to: - Phoenix Vessel Technology Ltd.
Contents
1. vessel technology ltd User s Guide to Phoenix Vessel Technology Limited 300 450 600 psi oide port pressure vessels 1 5 2 0 2 5 76mm 3 0 Model numbers 1908 3342 3348 bu 3649 3312 3605 3603 3641 3615 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 FORWARD 3 SECTION 1 Maintenance Guide 4 1 1 Removing End Cap from Vessel 4 1 22 Component Disassemby 1 3 Component Assembly 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 22 Operating Conditions 22 3 3 Safety Precautions 23 SECTION 4 Appendix 24 4 1 Spare Parts List 24 4 2 Assembly Drawing 1908 1 5 2 0 25 4 3 Assembly Drawing 3648 1 5 26 44 Assembly Drawing 3649 2 5 27 4 5 Assembly Drawing 3342 2 5 76mm 28 4 6 Assembly Drawing 3348 3 0 29 4 2 Assembly Drawing 3312 1 5 2 0 30 4 3 Assembly Drawing 3605 2 5 31 4 4 Assembly Drawing 3603 3 0 32 45 Assembly Drawing 3641 1 5 2 0 33 4 6 Assembly Drawing 3615 1 5 2 0 34 2 of 34 USER GUIDE MAY 2012 phoenix FORWARD Phoenix Vessel Technology is a major manufacturer of Glass Reinforced Pla2. ii NO 19 of 34 USER GUIDE MAY 2012 2 3 CONNECTIONS TO VESSEL 2 3 1 2 3 2 2 3 3 2 3 4 2939 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 vessel 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 6 per 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 purcha
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6. If removal is difficult then start at the point where the gap between two segments is greatest It may be of assistance to tap the backing plate with a wooden hammer shaft to free the segments 4 of 34 USER GUIDE MAY 2012 1 1 5 remove the end will require an extractor This is in three parts 1 PVC Connector this is threaded to fit the vessel end cap 2 Bridge piece 3 PVC nut to apply extraction load screw the PVC connector onto the product tube thread termination Grasp the remaining threaded portion of the connector gloves or a cloth are recommended to protect hands and pull with a gentle rocking motion 1 1 6 If the end cap cannot removed as indicated above then slide the metal bridge over the connector and use the PVC nut to apply extraction load 1 2 COMPONENT DISASSEMBLY 1 2 1 With the end fitting extracted Remove the adaptor from the end cap or from the end of the element 1 2 2 The hub to end cap joint should not be broken However if there is evidence of leakage of feed water into the product line then the hub may be removed from the end cap as shown NOTE Because of the tight fit removing the hub will result in damage to the pair of O seals Re place as necessary 1 2 3 The thrust ring only be removed by undoing the cap head screws 1 2 4 To remove the side port from the vessel the couplings must first be removed and the manifold moved away Then remove the cl
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8. FETY 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 NOTES located at the bot tom of the page which highlight potential problems areas and safety recommendations 3 2 1 Provide pressure relief device This should be set to no more than 105 of design pressure 3 2 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 2 3 DO NOT stand in line of end fitting while pressurisation takes place 23 of 34 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 34 USER GUIDE MAY 2012 WHOLIS 1195 IHA 1355 3 4179 Cj Te C OD 2 sk m Ao Ot NOIEEqE E Lep OH Fir TENE C EJ G L BD TW amp ONY CHER H DCTTVL ME Sec 3095 DLE 438 7i xw COO
9. amp system holding the side port in position There are two versions as shown below If a circlip is used 1 5 and 2 ports then remove the circlip with the tip if a screwdriver between the recess in the circlip and the body of the port Remove the circlip using a spirol twist If a clamp is used 2 5 and 3 ports then release the clamp using the apprpriate screwdriver and remove the plastic collar using a screwdriver to prise the collar appart and out of position For Model 1908 3648 3649 3312 For Models 3342 3348 3605 3603 3641 3615 phoenix 1 3 COMPONENT ASSEMBLY 1 3 1 Thoroughly clean all parts and check for the following a O SEALS cracked worn or cut areas b SIDE PORT corroded or distorted c END CAP Cracks around centre 1 thread 1 thread form damaged or truncated outer bearing edges worn threads for M10 cap head screws damaged SPIROLOC CIRCLIP broken or distorted e Retaining Rings Special Attention should be given to the GRP material Any signs of wear or damage Replacement Required f CAP HEAD SCREWS bent corroded or threads damaged g ADAPTOR cracks or scratches in sealing areas 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 NOTE It is recommended that O seals are replaced every time the end 15 rebuilt 1 3 3 Exami
10. ate the O seals with glycerine and push it into the end cap It will help if the hub is twisted as is pushed inwards 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 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 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 Check that there are no sharp edges to the membrane element which could scratch the vessel Contact the element manufacturer if these cannot be easily removed c 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
11. 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 C Push the elements into the vessel from the upstream end 12 of 34 USER GUIDE MAY 2012 1 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 ensure that the weight of the element is not taken on the interconnectors during loading The final element should be inserted the following distances MIN 10 8 274 Max 11 7 297mm in from the end of the vessel 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 i If the element is of the spigotted type ie has a core tube which is proud of the face of the element then shims may be required to ensure that the element remains connected to the pressure vessel end fitting These must be pla
12. ced between the adaptor and the product tube at the upstream end only ie at the opposite end to the thrust ring Shims may be used with any design of adaptor to reduce movement and prolong seal life MAXIMUM OF 8 AT UPSTREAM END OF VESSEL ONLY SHIM WIDTH 5MM NOTE Adaptors must be fitted to both ends of the stack of elements Catastrophic failure of the h product line can occur if adaptors are not fitted and pressure is applied The required number of shims may vary between 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 to 10mm 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 retaining ring segments fit into the groove in the vessel Finally subtract one more shim to ensure a safe float of 5 10mm 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 Push the thrust ring into position and secure it in place with the spring clip and cap head screws Remember to include the washers under the nut as per the following drawing NOTE Incorrect location of the thrust ring will da
13. f 34 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 09 329 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 vessel 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 34 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 EB EE CENE eo L1 TN 3 1 2 9 899 gt Ls 1 ss 29 centre support NO
14. ly inserted then the following checks should be carried out 1 Lubricate vessel surfaces with more glycerine and try again 1 The elements may have been pushed too far proceed as follows Remove large 8 diameter seal from end Remove adaptor from element 16 of 34 USER GUIDE MAY 2012 phoenix Remove small external O seal from adaptor and insert into end cap iii Without the O seals no effort should be required to insert the end cap if there is still insufficient space to insert the retaining rings then the elements have been pushed too far during loading Remove the last element by pushing it through the vessel taking care to support its weight as it emerges Refer to Section 1 4 Loading Membrane Elements further information 1 5 5 With the end fitting in place insert the two identical segments with the short sides together at the 12 o clock position then fit the segment containing the hole by sliding downward and between the other two Fix with the caphead screw by aligning with the hole in the end plate Must be tightened to 8 Nm 4 8 NOTE Remember to refit all O seals thrust ring 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 o
15. mage the membrane elements NOTE Please ensure the holes in the thrust ring are aligned with the ports in the vessel NOTE Please ensure plastic screws in thrust ring are tightened sufficiently to avoid movement during operation phoenix 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 very 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 end cap with glycerine particularly the large 8 diameter O seal 1 5 4 Insert end cap squarely into the vessel body sufficient to allow the segmented retain ing rings to be inserted fully into the groove in the end of the vessel If the end fitting is dif ficult to push into the vessel then use the wooden shaft of a hammer to tap it into position 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 If the end cap cannot be easi
16. ne the sealing surface of the vessel side port Remove any debris by flushing with water or by using a clean cloth Stubborn debris which adheres to the sealing surfaces may be removed by lightly polishing 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 Afterwards remove any debris with water or by using a clean cloth Apply glycerine lubricant to vessel surfaces and fit the side port into position using the insertion tool shown This has a small lip on its outer edge which pushes the seal into position without damaging it 9 of 34 USER GUIDE MAY 2012 For Models 3342 3348 3605 3603 1908 3648 3649 3312 3641 3615 1 3 4 Push the side port fully home using the compression tool until the circlip groove emerges from the vessel port Carefully fit the spiroloc circlip so that it does not distort ie aim to fit it into the victaulic groove first before engaging it into the circlip groove Then winde circlip into it s finla positionposition For Model 1908 3648 3649 3312 For Models 3342 3348 3605 3603 3641 3615 NOTE Lubricate the O Seals with Glycerine Do not use grease as this may impair the perfor mance of the membrane elements 1 3 5 Fit the O seals into the grooves the adaptor hub and end 1 3 6 If the adaptor and hub was removed earlier then lubric
17. ser 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 34 USER GUIDE MAY 2012 phoenix 3 2 OPERATING CONDITIONS DESIGN SPECIFICATION Internal Diameter Length Working Fluid Design Pressure Test Pressure Design Temperature Expansion Vacuum condition Support Position To fit any 8 nominal diameter element Up to 300 of membrane elements Water brackish 300 psi 20 7bar 1 1 times design pressure for upto 15 minutes maximum 20 to 1139 F 7 to 459 0 5 to 0 6 mm per metre length of vessel at design pressure Down to 14 5 psi 0 bar absolute 2 supports for 1 to 4 5 40 elements 3 supports for 5 to 7 5 40 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 Alternative materials are available on request NOTE The vessel should not be allowed to freeze solid This will damage the vessel wall and make replacement necessary 22 of 34 USER GUIDE MAY 2012 phoenix 3 2 SA
18. stic Pressure Vessels which are used as housings for 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 series of 8 Side Ported pressure vessels which have 1 female product tube connection The following Assembly Drawings are applicable 1 1 1908 8 300 psi Model 2 1MNC 3648 8 300 psi Model 3 1MNC 3649 8 300 psi Model 4 1MNC 3342 8 300 psi Model 5 1MNC 3348 8 300 psi Model 6 3312 8 450 psi Model 7 1MNC 3605 8 450 psi Model 8 1MNC 3603 8 450 psi Model 9 1MNC 3641 8 450 psi Model 10 3615 8 600 psi Model 3 of 34 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 hexagonal T bar or Allen key remove the caphead screw located in end of the vessel 1 1 4 Remove the segment retaining rings
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