HARBIN ROPV INDUSTRIAL CO.

, LTD

8 Inch Side Port FRP Pressure Vessel

User Manual

Models:

R8040B300S,R8040B450S

Headquarters

Tel：(+86)451-82267301
Fax：(+86)451-82267303
Email: sales@ropv.com.cn
Website: www.ropv.com.cn
Certifications

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 Table of Contents

CHAPTER 1 GENERAL PRODUCT DESCRIPTION...................................................................................... 5

PRODUCT IDENTIFICATION............................................................................................................................. 5
OPERATION SPECIFICATIONS.......................................................................................................................... 6
VESSEL USE AND PRECAUTIONS......................................................................................................................6

CHAPTER 2 INSTALLATION...................................................................................................................... 8

CHAPTER 3 PIPING CONNECTIONS......................................................................................................... 9

3.1. PERMEATE PORT CONNECTIONS 9

3.2. FEED/CONCENTRATE PORT CONNECTIONS 9

CHAPTER 4 MAINTENANCE GUIDE....................................................................................................... 12

4.1. PREVENTIVE MAINTENANCE 12

4.2. OPENING THE VESSEL 12
4.3. HEAD DISASSEMBLING. 15
4.4. HEAD ASSEMBLY CLEANING AND INSPECTION. 17
4.5. CLEANING AND INSPECTION OF THE NON-METALLIC COMPONENTS. 17
4.6. HEAD ASSEMBLY 18

CHAPTER 5 LOADING/REPLACING MEMBRANE ELEMENTS................................................................ 22

5.1. INSPECTION 22
5.2. DISASSEMBLE MEMBRANE COMPONENTS 22
5.3. UNLOAD THE MEMBRANE 22
5.4. CHECK AND MAKE SURE THE HEAD IS ASSEMBLED ACCORDING TO HEAD DISASSEMBLY AND HEAD ASSEMBLY. 22
5.5. VESSEL CLEANING AND INSPECTION 22
5.6. INSTALL THE HEAD AT THE CONCENTRATION SIDE 23
5.7. INSTALL LOCKING KIT SEGMENT AT CONCENTRATION SIDE. 24
5.8. LOAD MEMBRANE ELEMENTS FROM THE FEED END OF THE VESSEL 24

CHAPTER 6 CLOSING THE VESSEL..........................................................................................................26

6.1. PRE-CLOSING INSPECTION 26

6.2. INSTALL HEAD AT THE FEED END (UPSTREAM) 27
6.3. INSTALL LOCKING KIT SEGMENT AT FEED END 27

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6.4. INSTALL THE PERMEATE PORT PLUG. 28
6.5. RECONNECT THE PIPES 28
6.6. CHECK AS PER APPENDIX I PRE-RUNNING CHECK LIST 28

CHAPTER 7 HANDLING AND STORAGE................................................................................................. 29

7.1. VESSEL HANDLING PRECAUTIONS 29

7.2. STORAGE REQUIREMENTS 29

CHAPTER 8 BREAKDOWNS AND SOLUTIONS....................................................................................... 31

8.1. LOCKING KIT SEGMENT AND RELATED ISSUES. 31

8.2. HEAD AND RELATED ISSUES. 31
8.3. VESSEL AND RELATED ISSUES. 32
8.4. FEED/CONCENTRATE SIDE PORTS AND RELATED ISSUES. 33
8.5. LOW PERMEATE WATER QUALITY 34

CHAPTER 9 SERVICE GUIDE................................................................................................................... 36

APPENDIX I 37
PRE- RUNNING CHECK LIST 37
APPENDIX II 38
MAINTENANCE CHECK LIST 38
APPENDIX III 39
ROPV LIMITED WARRANTY 41

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 Chapter 1 General Product Description

ROPV pressure vessel is designed to withstand 6 times the designed pressure before a
catastrophic failure occurs. As a safety precaution the housings are designed for a full
body leak at 4 times the design pressure to keep catastrophic failure from happening.
Each standard vessel is carefully inspected and a hydro-test is performed to ensure its
reliability before delivering from the plant.
ROPV Pressure Vessels are designed to provide safe operation over a long service life if
properly installed, operated, and maintained. The vessel may cause loss of life, severe
bodily harm, or property damage if improperly installed, operated, or maintained. Read
and understand all guidelines provided in the vessel User Manual. Observe every
precaution contained therein. Failure to do so may result in malfunction and potential
catastrophic failure. It is recommended that only qualified technicians experienced in
servicing hydraulic systems work with this vessel. Misuse, incorrect assembly, or use of
damaged/corroded components may result in catastrophic failure. ROPV Pressure
Vessels are design and manufacture in accordance 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 30 S - 6 (W)
0

ROPV Paint Color White

8 Inch Diameter Membranes per
Membrane Vessel
Feed/Concentrate
Membrane Length Side Port
40 Inch Maximum Operating
B Series Pressure (PSI)

R 80 40 B 30 E - 6 (B)
0

Paint Color Blue

Feed/Concentrate
End Port

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 Operation Specifications
R80 300S Design Pressure: 300PSI / 2.1Mpa / 21Bar
R80 450S Design Pressure: 450PSI / 2.1Mpa / 21Bar
Max. Permeate Pressure: 125PSI / 0.86Mpa / 8.6 Bar
Min. Operating Temp.: 14⁰F / -10⁰C
Max. Operating Temp.: 150⁰F / 65⁰C
Factory Test Pressure: ASME: 1.1x Design Pressure
Standard: 1.5x Design Pressure
Operating pH Range: 3 – 11
Cleaning pH Range: 2 – 12 (less than 30 minutes)

Vessel Use and Precautions

 Do not allow the vessel to fall or impact on the ground or other object.
 Use padding to protect the vessels during handling to prevent damage.
 Pressure up to the design pressure (PSI) of the specific model being used.
 Vacuum conditions should be avoided with vacuum breakers.
 Accommodates standard 8” nominal diameter spiral-wound elements.
 Read and follow the membrane manufacturer installation instructions along with this
manual.
 The required vessel/element interface hardware is supplied with the vessel. Ensure that
an element adapter is installed at each end of the vessel before use.
 Vessel expands under pressure and careful consideration must be taken when installing
straps/saddles and system connection piping.
 Installation with the straps/saddles provided is strongly recommended
 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
engineering drawing.
 Do not over tighten the straps – vessel must be allowed to expand under operation.
 Maximize the connection flexibility to allow for vessel growth under pressure.
 Align the side ports with the system manifold, correcting any misalignment before final
installation.
 Provide overpressure protection in the system safety devices.
 Inspect end closures regularly for signs of corrosion. Immediate corrective action
and/or replacement are suggested in case of corrosion.
 Thrust Ring must be installed at the downstream end of the vessel.
 Relieve system pressure before working on the vessel.

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 Do not attempt to over-tighten the Permeate Port connections as this may damage the
end closure. One turn past hand tight should be sufficient.
 Never operate the vessel in excess of its ratings. This may void the warranty and cause
bodily or property damage.
 Do not operate the vessel permeate port over 125PSI.
 Flush the vessel with permeate before system shutdown to reduce the chance of
corrosion.
 Do not install the vessel under direct sunlight.
 Operate the vessel within the recommended pH range - Operating pH Range: 3 – 10,
Cleaning pH Range: 2 – 12 (less than 30 minutes).
 Minimize membrane movement by careful shimming the membrane column.
 Failure to understand and follow all precautions may void warranty and result in
catastrophic failure of the vessel.
 These guidelines are subject to change. Please check with ROPV to ensure that the User
Manual is the latest version for the vessel model being used.

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 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 3 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
within3~5N.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.

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 Chapter 3 Piping Connections
Enough room shall be reserved for both axial and radial expansion of the vessel in the
design of the manifolds and pipelines; otherwise the vessel and other components of the
system could be damaged. Careful reading of this chapter will facilitate safe and normal
working conditions of the vessel and pipelines.

3.1. Permeate Port Connections

3.1.1. Use flexible connections to reduce vibration impact.
3.1.2. A U swan-neck tubing with flexible connectors at both ends, or one piece of
flexible soft pipe should be used for permeate port connections.
3.1.3. Extra and independent support shall be provided for permeate port pipelines
rather than using permeate port as support.
3.2. Feed/Concentrate Port Connections
3.2.1. Use flexible grooved couplings (IPS).
3.2.2. Do not connect any manifolds rigidly to the vessel.
3.2.3. Manifolds must be supported independently.
3.2.4. Manifold span should be greater than vessel span to allow for vessel growth
under pressure.
3.2.5. To reduce the risk of stress concentration we recommend that “two IPS
standard flexible couplings and one piping section” are used to connect the
Feed/Concentrate ports and manifold ports; this method lowers
requirements for housing alignment and the position accuracy of the
manifold welds. However, this method will increase the initial cost as shown
in figure 1.1.

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

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 installation position of the housing should be accurately controlled to ensure
the proper alignment of the manifold and the Feed/Concentrate ports.
3.2.7. Install the vessel correctly: Make sure to align the Feed/Concentrate ports
and the manifold ports at a distance in accordance with the direction of
coupling manufacturer.
3.2.8. Connecting the vessel and the manifold: Since only one IPS coupling is used to
connect directly to the manifold precautions shall be taken to ensure
additional flexible space is provided for the connection of vessels and
manifolds by adding an extra IPS coupling to the manifold, as shown in figure
1.2.

3.2.9. Slight angle between manifolds and F/C ports using IPS standard clamp for
connection is acceptable. However, high accuracy in alignment is required.
Misalignment in any direction should be avoided and keep to a minimum as
much possible since it will generate mechanical stress concentrations that
will damage the membrane housing.
3.2.10. Verify the alignment: When connecting two vessels together port to port
any difference in the length of the port to port from one vessel to another
should be noted. The difference should be distributed between the opposing
side ports. As an example a difference of 2mm in the port to port of the two
vessels should result in a 1 mm of misalignment on each end (see figure 1.3)
The tolerance of the port to port will dictate the maximum allowable
variation. Please refer to the engineering drawing for specific tolerances.
Excessive force to tighten the couplings is an indication of misalignment.

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Figure 1.3

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 Chapter 4 Maintenance Guide
4.1. Preventive Maintenance

Periodical cleaning and maintenance of the vessel and replacement of damaged

components is essential to ensure a safe and normal operation of the vessel over a long
service life.
As a recommendation we suggest to follow the Prevention Checklist below:

End closures.
 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.

DO NOT Service any component until you verify that

system pressure is fully relieved from the vessel and the
system is completely shut down.

4.2. Opening the Vessel

4.2.1. Shut Down System and Relieve System Pressure – The system must be
shut down and all pressure relieved before conducting any maintenance or
repair on the vessel. Read and follow all related guides provided by system
provider.
4.2.2. Disconnect permeate port piping. Unscrew and remove the permeate port
piping using a wrench. Pay attention to the thread-turning direction to
prevent any damage to the permeate port due to reversed turning or over-
turning.

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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 brush or scrubbing pad, while flushing with water. Damaged
components should be replaced with approved components from ROPV.
4.2.4. Remove the locking kit segment screws using a hex wrench.

Figure 2.1

4.2.5. Lift the locking kit segment out of the retaining groove using a screw
driver. Should the assemblies be difficult to remove, it may be necessary to
rock the head slightly or tap the head inward with a rubber mallet. Remove
the end closure. It is recommended to use dedicated end closure removal
tools from ROPV.
4.2.6. Remove the Head Assembly with One of the Following Techniques
4.2.6.1. ROPV Head Removal Tool– A head 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.

Figure 2.2 ROPV Head Removal Tool

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 4.2.6.1.1. Thread the center piece into the permeate port of the head
assembly, to hand tight. Do not over tighten the center piece
(Fig. 2.3).

Figure 2.3 Figure 2.4

4.2.6.1.2. Place the bearing block at the end face

4.2.6.1.3. Thread the position nut into the center piece
4.2.6.1.4. Turn bearing rod clockwise. The head will move with the
bearing rod as it moves toward the end of the vessel. You will be
able to remove the head once it has cleared the retaining groove
area of the vessel.

Figure 2.5 Figure 2.6

4.2.6.2. Alternative Head Removal – It is possible to remove the head assembly

without the ROPV head removal tools. A 1” NPT Male threaded piece of
PVC (or 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.

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4.3. Head Disassembling.

Read this article carefully before disassembling the head assembly to

prevent damaging its components.
4.3.1. Inspection: Make sure that the end cap is removed from the vessel
according to <Opening the Vessel>
4.3.2. Remove the adaptor and seals: Hold the bearing plate tightly with one
hand and pull the adaptor out of the permeate port with the other hand;
remove the adaptor seals and the sealing plate seals.
4.3.3. Remove the permeate port locknut: Remove the locknut using a
dedicated wrench. The locknut is left hand threaded and must be turned
clockwise to be removed.

Figure 2.7 Remove the locknut Figure 2.8 Remove sealing plate

4.3.4. Separate the bearing plate and sealing plate. Pull the sealing plate with
one hand to separate it from the bearing plate.
4.3.5. For parted seal plates, pull the permeate port out of the sealing plate
and remove the permeate port seals and the seals inside the sealing plate.

Figure 2.9

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 4.3.6. Remove the permeate port seals.

2.10 Remove seals

Carefully remove the seals to prevent damage to the

NOTE

sealing surfaces. It is recommended to replace all used

seals with brand new seals.

Figure 2.11 Head breakdown figure 1（sealing plate）

Components：sealing plate, adaptor，bearing plate，permeate port plug，permeate port
locknut，seals.

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 Figure 2.12 Head breakdown figure 2（parted sealing plate）
Components：sealingplate，permeateport，adaptor，bearingplate，plug，permeate port
locknut，seals.

4.4. Head Assembly Cleaning and Inspection.

Please read this section carefully before making decisions and taking
measures on component structure or corrosion problems. Please combine the
operational experience with this manual to deal with corrosion and
component damage. You can refer to <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.
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.
4.5. Cleaning and Inspection of the non-metallic components.

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 Non-metallic components include sealing plate, permeate port, adaptor,
permeate port locknut, permeate port plug and all seals.
4.5.1. Inspect components for scale, corrosion or salt deposit. Place the
components into a bucket filled with mild soap solution and clean them to
remove the deposits.
4.5.2. Flush all components with clean water.
4.5.3. Dry the components with compressed air or a clean and dry towel.
4.5.4. Inspect all components carefully for any structural defects or damage in
the seals. For example, cracks in the permeate port or the locknut, damage
in the threads; aged, deformed or damaged seals. Replace any damaged or
defective component with new ones
4.5.5. Replace all components that need to be changed upon inspection
4.5.6. Inspect carefully the Feed/Concentrate ports and attachments to the shell
to ensure that connections and seals are structurally sound. Please contact
ROPV for any questions.
Please do not conduct any repair work before consulting with the manufacturer
for guidance, except for replacing head components.

If chemical reaction problems occur like cracks or

NOTE

discoloration on the vessel or its components, please

contact please contact ROPV at: service@ropv.com.cn

4.6. Head Assembly

Read and follow this section. Incorrect assembly may result in catastrophic head
failure.

4. Lubricate and install the seals.

ATTENTION

We recommend using brand new seals for head

assembly.
Lubricate seals using glycerin or silicone base
lubricant.

4.6.1.1. Lubricate the permeate port seals and place them in the grooves.

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 Figure 2.13 Install the permeate port seals

4.6.1.2. Head with parted sealing plate. Lubricate the sealing plate seal and
place it in the groove located on the inside diameter of the sealing plate.
Lubricate the permeate port seals and place them in the grooves located
on the inside diameter of the permeate port. Lubricate the permeate
port seals and place it onto the outer edge of the permeate port.
4.6.1.3. Lubricate the adaptor seals and place them in the grooves of the adaptor.

Figure 2.14 O-ring installation for parted seal plate

Figure 2.15 Adaptor seals installation

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4.6.2. Assemble the sealing plate and bearing plate
4.6.2.1. Assemble parted sealing plate. Apply a thin layer of lubricant onto the
surface of the permeate port and push the permeate port through the
hole of the parted sealing plate.
4.6.2.2. Insert the threaded end of the permeate port through the hole of the
bearing plate until full contact of the sealing plate and bearing plate.

Figure 2.16 Assembling parted seal plate Figure2.17 Assembling 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.

Figure 2.18Locknut installation Figure 2.19 Adaptor installation

4.6.3. Install the adaptor. Insert the end without seals into the hole of the
permeate port.
4.6.4. Install the head O-ring. Lubricate the O-ring and seat it into the groove
located on the outside diameter of the sealing plate.

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Figure 2.20Head assembly

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 Chapter 5 Loading/Replacing Membrane Elements
Read all parts of this section before replacing membrane elements. This article is
for reference only; load/unload the membrane elements according to the
membrane manufacturer requirements.
Membrane elements must be loaded at the feed (upstream) end of the vessel, and
unloaded through the concentrated (downstream) side of the vessel. Always
remove and install elements in the direction of feed flow.
Make a matching list for the removed membrane and the vessel to avoid possible
disorder during membrane loading
Steps:
5.1. Inspection
5.1.1. Verify all pressure has been relieved from the vessel, following system
manufacturer’s recommendations.
5.1.2. Ensure the vessel is opened according to Opening the Vessel.
5.2. Disassemble membrane components
5.2.1. Remove the thrust ring located at the concentration side.

5.2.2. Remove the adapter from the membranes on both sides of the vessel.
5.3. Unload the membrane
5.3.1. Clean off any lubricant residue or salt build up from the inside diameter at
both ends of the vessel.

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

Be careful not to scratch the inner

surface of the vessel while removing or
installing the membrane elements.

5.4. Check and make sure the head is assembled according to Head
Disassembly and Head Assembly.
5.5. Vessel cleaning and inspection

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 Figure2.21 Side Port and vessel inspection
5.5.1. Clean the inner surface and groove of the vessel by removing the residue
or corrosions with a mild soap solution and then flush with clean water.
5.5.2. Check if there is any damage to the inner surface of the vessel. If yes,
Please change the vessel.
5.5.3. Carefully inspect the F/C ports and the shell to ensure intact sealing,
structure and material. Any questions, please contact ROPV

5.6. Install the head at the concentration side

5.6.1. Apply a thin layer of glycerin within 50mm from the groove on the inner
surface of the vessel at the concentrate (downstream) end of the vessel.
5.6.2. Apply a thin layer of glycerin on the surface of the head O-ring for the
concentrate (downstream) end of the vessel.
5.6.3. Install the thrust ring onto the head for the concentrate (downstream)
end of the vessel.

Figure2.22 Install the thrust ring

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 5.6.4. Grasp the permeate port and the locknut to keep the head and the vessel
in the same axis and push the head into the vessel until some resistance can
be felt. Then continue pushing the head slowly into the vessel until it
reaches over the groove. Please do not push the head too much over the
groove since the seals may be damaged if the head needs to be pulled back.
If it is difficult to push the head with hands, a rubber mallet can be used to
hit the head until the head reaches its place.
5.7. Install locking kit segment at concentration side.
5.7.1. Inspect the groove and ensure it is clean and free of residues. Use
compressed air to dry the groove if available or use a clean rag to dry it.
5.7.2. Apply lubricant like glycerin onto the locking kit segment screws to
prevent salt deposits to buildup. Position the locking kit segments into the
groove.

Figure 2.23 Install locking kit segment

5.8. Load membrane elements from the feed end of the vessel
5.8.1. Inspect and confirm there are no scratches on the inner surface of the
vessel.

5.8.2. Inspect and ensure there is nothing on the outer surface of the membrane
that may scratch the inner surface of the vessel.
5.8.3. Using a clean rag or cotton and a mixture of glycerin and clean water at a
1:1 ratio ball lubricate the inner surface of the vessel.
5.8.4. Using a clean rag or cotton and a mixture of glycerin and clean water at a
1:1 ratio ball lubricate the membrane seal.
5.8.5. Load the membrane from the feed end of the vessel; ensure that the
membrane is properly orientated. If there are more than one membrane to
be loaded into the vessel, do not push the first membrane into the vessel
completely but reserve around 200mm to facilitate the connection of the

24
 next membrane.
5.8.6. Inspect and make sure the membrane interconnector is clean and intact.
Apply a thin layer of glycerin onto the interconnector seals without
excessive amount; otherwise the membrane may get contaminated. Install
the interconnector into the loaded membrane.
5.8.7. Install and connect the next membrane with the loaded one with the
interconnector.
5.8.8. Load all membrane elements in the same way. Push all the membranes
into the vessel until the adaptor at the concentration end is inserted into the
center hole of the first membrane and the membrane face is pushed against
the thrust ring.

Please ensure all membranes are in the same axis.

ATENTION

No load on the connection pipe, otherwise the

pipe or the membrane may be damaged.

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 Chapter 6 Closing the Vessel
Please read this article carefully. Incorrect assembly may result in catastrophic
failure.

Warning

Please read this article before closing the

vessel.DO NOT use corroded or damaged parts
to avoid catastrophic failure.Do not pressurize
the vessel before all closing steps are finished.

6.1. Pre-Closing Inspection

6.1.1. Inspect the head is assembled as per Head Disassembly and Head
Assembly
6.1.2. Verify that the membranes are loaded as per Loading/Replacing
Membrane Elements
6.1.3. Ensure the inner surface of the vessel is free of corrosion build up or
residue of foreign materials.

Figure 2.24 Vessel cleaning

and inspection

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.

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 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
6.2. Install head at the feed end (upstream)
6.2.1. Apply a thin layer of glycerin within 50mm from the groove on the inner
surface of the vessel.
6.2.2. Apply a thin layer of glycerin onto the head O-ring at feed end.
6.2.3. Grasp the permeate port and locknut; keep head and vessel in the same
axis. Push the head into the vessel until some resistance can be 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.

Figure2.25 Install head assembly

6.3. Install locking kit segment at feed end

6.3.1. Inspect the groove and ensure it is clean and free of residues. Use
compressed air to dry the groove if available or use a clean rag to dry it.
6.3.2. Apply lubricant like glycerin onto the locking kit segment screws to
prevent salt deposits to buildup. Position the locking kit segments into the
groove.

27
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.

Figure 2.26 Install permeate port plug

6.5. Reconnect the pipes

Reconnect the pipes as per Piping Connections.
6.6. Check as per Appendix I Pre-Running Check List

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 Chapter 7 Handling and Storage
Read this article carefully. Incorrect handling and storage may result in
catastrophic failure.
Check the packing conditions when accepting the goods. Contact the logistics
company at once in case of damaged vessel.
Slight damage in the outer surface of the vessel within the painting layer is
acceptable. Any query, please contact ROPV.

7.1. Vessel Handling Precautions

 Keep the vessel from falling down to the ground or colliding with other objects
when it is being moved.
 Special care should be taken if forklift or other machinery is used for handling
the vessel.
 Use padding to protect the vessels during handling to prevent damage.
 DO NOT Scratch or damage to the inner surface of the vessel.
 DO NOT lift the vessel from the Feed/Concentrate ports or permeate ports.
 DO NOT impose excessive external force on the vessel.
 DO NOT climb on the vessel.
 Damaged vessel must not be used.

7.2. Storage Requirements

 Do not store with other products.
 Make a list of product and spare parts before storage.
 Store vessels in their original packaging.
 Storage temperature range should be -10ºC~+50 ºC
 Storage humidity range should be 40%~70%RH；
 Store in a place with a light intensity of less than 100Lux；
 Store in a safe area to keep the vessel from shaking or falling.
 Height: not exceeding 3 packing units.

29
 Product quantity

Checking

Parts quantity

Checking packaging
Temp.-10ºC~+50ºC

Check storage conditions Humidi40%~70%RH

Light less than100Lux

Check height

Safe storage area

Finish the storage

Figure 2.27 Storage procedure

30
 Chapter 8 Breakdowns and Solutions
Please refer to this article for common breakdowns and solutions. The contents of
this section need to be used with good practical industrial experience. We
recommend that only engineers with extensive work experience conduct any
repair work.
8.1. Locking Kit Segment and Related Issues.
8.1.1. Locking kit segment screw is too tight to thread out.
Solution: Apply penetrating fluid (such as WD-40 or LPS-1) onto the locking
kit segment and tap it with a hammer until the screw can be threaded off.
Please take care not to contaminate the membrane elements.
8.1.2. Locking kit segment screw cannot be removed due to damage in screw cap or
threads
Solution: cut the locking kit segment screw off.
Tools: angle grinder, cutting disc, power cables, electric drill, M8 screw tap,
6mm stainless steel drill bit.
Steps:
- Cut the locking kit segment screw with angle grinder
- Use an electric drill with stainless steel bit with diameter of 6mm to drill the
rest of the screw out of the bearing plate. Please take care not to damage the
threads of the screw hole in the bearing plate.
- Make new threads for the screw hole in the bearing plate with a M8 screw
tap.
- Flush the residue with clean water.
ATENTION

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

8.2. Head and Related Issues.

8.2.1. Leakage in seals
Possibilities:
A. Deteriorated head seals after running for over 2 years
B. Seals are damaged due to improper installation
C. Seals are deformed due to the PH of the medium
D. Seals are deformed due to the temperature of the medium
Solution：
a. Check the composition, temperature, and PH of the medium.

31
 b. Replace the seals as per Maintenance Guide.
8.2.2. Sealing plate or permeate port is damaged.
Solution: Replace sealing plate or permeate port

There should be no more than 4 layers of seal tape on the

ATENTION

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.

8.2.3. Bearing plate is corroded due to leakage in vessel

Solution: Repair the leakage and replace bearing plate as per Vessel and Related
Issues.
8.3. Vessel and Related Issues.
8.3.1. Leakage in sealing surfaces.
Possible reasons:
 Scratches or damaged bore at the seal area location.
Solution:
For lite scratches, hand sand sealing areas using wet 600grit sand paper until a
smooth finish is achieved. For dip damage or scratches not affecting the
structural wall (.2 mm), epoxy or vinyl ester resin can be used to fill the damaged
surface.

8.3.2. Vessel is corroded or cracked.

Possible reasons:
 Ph out of range, medium is to acid or alkaline.
 Non-acid membrane shells mixed with acid-proof membrane shell.
Solution：
Inspect the cracks: If it is a high-pressure vessel or the cracks reach structural
layer (.2mm deep), the vessel must be replaced.
Check the medium: Check the PH range and adjust accordingly.

8.3.3. Body damage.

A. During transportation
B. During installation
Solution: replace the vessel if the body is seriously damaged; measures below can
be taken if there is only slight damage
Tools: painting gun, air compressor, electric dryer, angel sander and sanding disc,
louver blade.

32
 Materials: Epoxy resin and hardener, body filler and hardener, ROPV paint,
fiberglass mat.
Steps: First, use epoxy resin, mats, fiberglass mat to fill the damage, once the resin
is cured sand the excess until the surface is level and smooth; apply body filler if
necessary; last, paint with a painting gun.
ATENTION

For any leakage of Feed/Concentrate port, please

contact Harbin ROPV Industrial Co., Ltd

8.4. Feed/Concentrate Side Ports and Related Issues.

Please follow steps below to remove Feed/Concentrate side ports in case of
leakage.
A． Shut down the system and drain the vessel.
B． Disconnect the piping off the permeate port and Feed/Concentrate ports.
C． Open the vessel as per Opening the Vessel.
D．Remove the retaining ring from the leaking port.
E． Using a rubber mallet, tap the port in wards to remove the port.

When removing Feed/Concentrate ports, soft mats

ATENTION

should be placed inside the vessel to keep the inner

surface of the vessel from damaging by the falling F/C
ports

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)
Solution: adjust the manifolds and reconnect the pipes as per Piping Connections.
8.4.1. Feed/Concentrate Side Port Inspection and Installation.
Please follow steps below to install Feed/Concentrate side ports

33
 A. Clean ports- Remove the fouling or residue on the F/C ports with a mild soap
solution and flush them with clean water. Dry them with compressed air if
available or a clean towel.
B. Lubricate and install F/C ports seals- apply a thin layer of glycerin onto the
seals and seat them into the grooves in the F/C ports
C. Apply a thin layer of glycerin onto the inner side surface of the vessel’s ports.
Insert the F/C ports into the hole in the vessel from the inside the vessel and push
them out until the retaining ring grooves are visible from the outside of the vessel.

Do not to scratch the inner surface of the vessel’s

ATTN

side holes when installing F/C ports.

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.
Solution: Shimming the membranes.
a. Remove the head at feed end and adaptor as per Opening the vessel.
b. Remove the adaptor seals and the head O-ring. Insert the straight end of the
adaptor into the permeate hub far enough to be held by the adaptor sea. Align the
adaptor with the membrane and push the head carefully into the vessel until the
groove is exposed far enough to insert a locking segment into it. Slowly remove the
head with care and then check the size of the gap between permeate port and

34
adaptor. The number of 2mm shims needed to fill this gap will depend on the size
of the gap. Reinstall the adaptor seals and seal plate seal; slide shims on the flat
end of the adaptor and insert the adaptor into the permeate port hub. Shims must
be placed between the permeate port and adaptor.
c. Close the vessel as per Closing the Vessel.

35
 Chapter 9 Service guide
Dear users：
Thanks for choosing ROPV FRP pressure vessels. We provide you with the
following services according to our national laws and regulations (See ROPV
Limited Warranty for more details):
I．Quality warranty
ROPV promises to provide “one-year warranty and lifetime maintenance” on the
condition that the vessels are properly installed and operated.
II．Technical suppport
1 ． ROPV commits to reply users within 8 hours for their complain or technical
consultation.
2．ROPV commits to arrive at project site within 48 hours if needed.
III．Exclussions for the free service coverage
1 ． Damages caused by improper transportation, installation, operation and
maintenance
2．Damages caused by operation without sticking to the requirements in this manual
3．Invoices are altered or Inspection Certificate is not available
TIP:

Any problem, please contact via after-sales

hotline0451-82267309

Phone： 0451-82267301/02/06/08

E-mail: service@ropv.com.cn

Website：www.ropv.com.cn

36
 Appendix I
Pre- Running Check List

Name Drawing No.

Pressure rating Vessel No.

Items Status

Membrane is loaded as per requirements YES□ NO□

Membrane
Adaptor is installed as per requirements YES□ NO□
elements

Thrust ring is installed as per requirements YES□ NO□

All components are clean and in good conditions YES□ NO□

Vessel is installed and fixed as per requirements YES□ NO□

Vessel Head is assembled as per requirements YES□ NO□

Locking kit segment and securing ring (high

pressure vessels) are installed as per YES□ NO□
requirements
The pressure gage of closed vessel reads the
YES□ NO□
same as that of the system
Pipes are connected as per requirements without
YES□ NO□
stress concentration
Piping
connections
All piping components are in good conditions YES□ NO□

Installation staff: Installation date:

Inspector: Inspection date:

37
 Appendix II
Maintenance Check List

Name Vessel No.

Pressure rating Work pressure

Times of
Running time
maintenance

Item Status Treatment

Corrosion YES□ NO□

Deterioration YES□ NO□

Damage YES□ NO□

Leakage YES□ NO□

Inspector： Inspection date：

Maintenance staff： Maintenance date：

38
 Appendix III
Engineering drawing: Please contact ROPV for the most current vessel drawing.

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8 Inch Side Port FRP Pressure Vessel User Manual
 Page | 40
8 Inch Side Port FRP Pressure Vessel User Manual
 ROPV Limited Warranty

Harbin ROPV Industrial Co., Ltd (hereinafter called “ROPV”) vessels (the “Product”) are warranted to the original purchaser (the “Customer”) under normal use
and if installed, operated and maintained in accordance with applicable User Guides to be free of defects in material and/or workmanship for a period of one (1)
year from date of manufacture subject to the following. Any replacement Product or Part will be warranted only for the remainder of the original warranty
period or thirty (30) days, whichever is longer.
Exclusions from this Limited Warranty
The warranty shall be void if:
1. Defects are not reported during the warranty period.
2. The Product is subject to accident, damage, incorrect installation, mishandling, abuse, misuse, negligence or accident by any other party.
3. Problems caused by modification or alteration.
4. Chemical exposure or acts of nature.
5. Any item manufactured by other companies.
6. Wear on replaceable components under normal conditions – seals are excluded from this warranty.
Procedure for Obtaining Warranty Performance
ROPV reserves the right to determine if a reported defect is a breach of this warranty. This may require, at ROPV’s discretion, one or more of the following: 1. an
inspection or test of the Product and/or the system in which it was installed by an ROPV representative - the customer is responsible for arranging access to the
Product. 2. an inspection or test of the product and/or the system in which it was installed by the Customer. 3. an inspection or test of the product and/or the
system in which it was installed by third party inspector appointed by ROPV. 4. return of the Product to ROPV’s factory for inspection or testing. This is not a
statement of limitations for warranty performance and ROPV reserves the right to conduct warranty performance outside of the items shown.
If the Product is found by ROPV to be defective under the terms of this warranty, ROPV will perform one of the following at its option: 1. supply a substantially
similar replacement part based on FOB factory terms. 2. conduct a field repair of the Product. 3. issue a credit for the original cost of the Products. This is not a
statement of limitations for warranty performance and ROPV reserves the right to conduct warranty performance outside of the items shown.
Products returned to ROPV for inspection or testing must be shipped freight prepaid at the Customer’s expense. If a breach of warranty is confirmed, ROPV will
bear all costs related to the inspection and testing. If the Product failure is found to be caused by cause other than breach of warranty, all costs related to the
inspection and testing of the Product will be borne by the Customer. This includes a USD$500 per day fee and all related travel expenses.
All reported defects must be submitted to ROPV in writing.
Disclaimer
ROPV makes no expressed or implied warranty other than that specifically set forth in this warranty statement. ROPV disclaims any warranty of merchantability
or of fitness for a particular purpose.
ROPV’s liability under the terms of this warranty shall not exceed the purchase price of the Product which are claimed to be defective. ROPV shall not be liable
for any consequential or incidental damages whatsoever, including but not limited to injuries or damages to person or property, loss of business profits,
business interruption, loss of use, cost of removing/installing Products, or the claims of third parties.
Warranties or Representations by Others

Page | 41
8 Inch Side Port FRP Pressure Vessel User Manual
No agent, employee, dealer, or other person has any authority to make any warranties or representations concerning ROPV or the Product. ROPV is not
responsible for such claims of warranty or representation.

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8 Inch Side Port FRP Pressure Vessel User Manual