Pentair CodeLine 40E60 User manual

Product Bulletin 526004 Rev. C
40E60 Brackish RO Pressure
Vessels
User’s u ide
DAN ER - HI H PRESSURE DEV ICE
This vessel may cause loss of life, severe bodily harm, or property damage if not correctly installed, operated and
maintained. Read and understand all guidelines given in this bulleting before attempting to open, operate or service
this vessel. Failure to follow these guidelines and observe every precaution will result in malfunction and could
result in catastrophic failure. Misuse, incorrect assembly, or use of damaged or corroded components can result
in
high-velocity release of the end closure. We recommend that only a qualified technician experienced in servicing
high-pressure hydraulic systems open, close and service this vessel.
Important Safety Pr ecaution s
Do...
Do...
Do...
Do...
Do...
read, understand and follow every guide-
line in this bulletin. Failure to take every
precaution may void warranty and could
result in catastrophic failure.
install in an area where a vessel or piping
malfunction that result in water leakage
would not damage sensitive or expensive
equipment, such as electronic components.
verify that head locking components are
properly placed and secured.
inspect end closures regularly, replace
deteriorated components and correct
causes of corrosion.
follow membrane element manufacturer’s
recommendations for loading elements into
the vessel (see Replacing El e m e n t s ).
Do not...
Do not...
Do not...
Do not...
Do not...
Do not...
Do not...
Do not...
operate vessel at pressures and tempera-
tures in excess of their specific rating.
service any component until you verify that
pressure is fully relieved from the vessel.
use corroded components. Use of such
components may result in catastrophic
failure.
pressurize vessel until after visually inspecting
to ensure that the spiral retaining rings is
correctly installed and seated in their grooves.
tolerate leaks or allow end closures to be
routinely wetted in any way.
use excessive silicone lubricant.
pressurize vessel without element in place
unless perme ate ports are plugged
internally.
overtighten fittings in ports.
Do not...
Use petroleum products on Noryl components.
Do not...
Allow petroleum or silicone based products to
come in contact with membrane elements during
installation or maintenance.
Do not ...
Do not ...
Use the vessel at negative pressure
Stand or climb on the pressure vessels, or the
feed / concentrate or permeate ports.
eneral
I nformat ion
The 40E60 RO Pressure Vessel Housings are designed
to be used in water desalination systems. Any make of
4-inch nominal diameter spiral-wound element may be
used. The vessels utilize a fiberglass reinforced plastic
shell for superior corrosion resistance. However, metallic
parts of the vessel may be subject to corrosion, which
can result in an unsafe condition. The fiberglass shell
can be damaged by rigid clamping, impact, scratches
or abrasion.
The information and guidelines incorporated in this
User’s uide are intended only as a supplement to
good industrial practice. Full responsibility for correct
operation and maintenance of vessel remains with the
user.
This guide should be used in conjunction with drawing
number 518017.
When properly installed and maintained, 40E60
vessels can be expected to provide safe operation over
a long service life.
40E60 User uide Rev. C Updated 05/07/2013 Page 1 of 9
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Installation
Regardless of when or by whom your vessel may
have been installed, there are a few quick checks
you should make before use. Check that each
vessel is:
M o u n t e d w i t h c o m p l i a n t m a t e r i a l
(Polyurethane saddle) between the fiberglass
shell and any rigid frame.
Free to expand under pressure - shell not
clamped rigidly in place, no rigid piping
connections to port fittings.
Not used in any way to support other
components such as piping, manifolds
hanging from ports.
Figure 1: Section Through End
C l osu r e
Dwg Re f Qty Per Item # Des c ri pt i o n Ma t eri a l s
She ll
1 1 Shell Filament Wound epoxy/glass
composite. Head locking grooves
internally wound in place. Shell
exterior coated with white high
gloss polyurethane paint.
H e ad
2
2
5
0
42
0
E
n
d
P
l
ug
Engineerin
g
Thermoplasti
c
3 2 50440 Bearing Ring Nickel Plated Alloy Steel
4
2
4
5
31
7
P
l
ug
Se
a
l
E
t
h
y
l
e
n
e
Pr
o
p
y
l
e
n
e
O
-
r
i
n
g
5
2
4
5
29
4
A
d
a
p
t
e
r
S
e
a
l
E
t
h
y
l
e
n
e
P
r
op
y
l
e
n
e
O
-
rin
g
Head I nterl oc k
6
2
4
5
26
0
R
e
t
ai
n
i
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g
Ri
n
g
31
6
SS
T
10 2
A/R
Adapter Engineering Thermoplastic
1
1
A/R
A/R
PWT
S
e
a
l
E
t
h
y
l
e
n
e
po
l
y
prop
y
le
n
e
O
-
r
i
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g
Vessel Su pport
7
*
2*
*
45058 Saddle Engineering Thermoplastic
8
*
2*
*
4745
9
Stra
p
Assembl
y
30
4
SS
T
-
PV
C
Cushio
n
9
*
4
47458 Strap Screw 5/16-18 UNC, 18-8 SST
*
Not
e
item
s
7,
8
an
d
9
no
t
show
n
i
n
th
e
abov
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cros
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sectio
n
** 3 each furnished with length code 4,5 and 6
Page 2 of 9
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Page 3 of 9
WARNIN
Relieve pressure from vessel
before beginning this procedure.
CAUTION
DO NOT tap on fittings as this
could damage the ports.
Opening the
Vessel
Remove the Retaining Ring from the gr oove
Contamination Remov al
Metal oxidation products and mineral deposits can
interfere with vessel disassembly. Remove all
foreign matter from both ends off vessel as
follows:
1.
Remove contaminants using a small wire brush
or suitable abrasive (such as medium-grade
ScotchBriteTM).
Cleaning inside the vessel
2. Flush away loosened deposits with clean water.
1.
Lift the tabbed end of the retaining ring up out of the
stainless steel groove in the shell and then away
from the head so that it rests in the end margin of the
vessel. This is best accomplished by using CodeLine
®
Removal Tool, part number 50303, which is available
from your supplier. This can also be accomplished
using a screwdriver and a pair of pliers if the tool is
not readily available.
With the removal tool the retaining ring can be lifted
upward by simply rotating the tool counterclockwise
after inserting it over the tab on the retaining ring.
(Use the smaller hole). Hold the tool flat against the
end margin and parallel to the vessel bore. It is them
possible to pull the end of the retaining ring straight
out. The retaining ring ,ay snap back into the groove
if this alignment is not closely adhered to. If the
retaining ring is difficult to remove, try soaking with
a release agent such as LPSTM or WD40
TM
, being care-
ful to avoid any contamination of a membrane
element.
Removing the Head
The head assembly is shown in Figure 1.
Remove head as follows:
Disconnect Permeate Piping
1. Disconnect permeate piping as required at
nearest convenient joint, being careful not to
place undue stress on the threaded connections
of the plastic permeate port(s).
Retaining Ring Removal Tool
When using screwdriver and pliers, pry the tabbed
end of the retaining ring out of the stainless steel
groove with the tip of the screwdriver. Once the end
of the retaining ring is clear of the groove, grab the
tab with the pliers and pull towards the end of the
vessel until the end of the ring is resting in the end
margin of the shell.
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Page
4
o
f 9
Opening The Vessel (co
ntd...)
2. Remove the 4” retaining ring from the stainless
groove in the shell by rotating your finger behind
the ring as it continues to exit the groove.
4. Remove and discard plug seal, taking care not to
scratch or otherwise damage the sealing surfaces.
5. Repeat above procedure for the opposite end of
the vessel.
6. As soon as possible after removal, disassemble
and check all head components, as described in
Rebuilding the Head and Refurbishing Parts.
Removal of Retaining Ring
3. Once the retaining ring has been removed, examine
the area for burrs or dings which could damage
the
head or membrane. If necessary, use ScotchBrite
TM
or 600 grade sandpaper to smooth the area.
Removing Head Assembly
1. Using a mallet, tap the head assembly lightly. Do not
use a metal component to tap the head assembly.
2. Install a ½”NPT x 6” long nipple into the product
port of the head on one end of the vessel.
3. rasp the nipple and pull the head straight out. A
.
small amount of side-to-sidemovement may be
necessary to move the end plug. Care should
be taken to avoid placing too much stress
on the product port threads.
Removal of Head Assembly
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Page
5
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NOTE
Always remove and install element in
the direction of feed flow. The feed
end (upstream end) is the end plumbed
most directly to the p ump.
CAUTION
When lubricating the vessel chamfer ,
wear protective gloves or finger cots t o
prevent cuts or penetration of
fiberglass.
Replacing
Element s
The following procedures are provided for inform-
ation only. Elements should be installed in accord-
ance with the element manufacturer’s recommend-
ations. Where conflicts exist, contact the element
manufacturer or Pentair Water for clarification.
To replace elements, proceed as follows.
Removing
El ements
4. Install adapter if required into one end plug.
At
downstream end of vessel, orient end plug
ports into desired position and push plug fully
into vessel. A sharp, forceful thrust may be
needed to enter plug seal into the vessel bore.
1.
Remove heads from both ends of vessels as
described in Opening the V e ss e l .
2.
Push element out of vessel from the upstream
end.
3. For multi-element vessels, remove the inter-
connectors and retain for reinstallation.
Inserting E lements
Installation of the End Plug Assembly
into the vessel
5. Carefully insert retaining ring into its groove.
This is done by inserting the lead end of the
spiral retaining ring (end without bent tab) into
the stainless steel retaining ring groove located
in the shell, and slowly pushing the remaining
turns into the shell.
1. Ensure that heads are available in clean,
as-new
condition before proceeding. (If in doubt as to
head condition see section on inspecting parts,
page 9).
2. Check that all required elements are ready for assem-
bly, with no dings or other damage which could
scratch the inside of the vessel.
3. Check that the interior of the vessel is clean and free
o f b u r r s , s h a r p e d g e s o r o t h e r d a m a g e .
Remove any residual lubricant from the vessel bore
and work a fresh, thin film of Parker-Super O-Lube
TM
silicon lubricant into the lead-in chamfer and an area
approximately ½ inch in from the chamfer
Inserting Retaining Ring into the gr oove
6. Check that the spiral retaining ring is fully seated
in the groove. If it is not, remove and check for
foreign material that is causing the spiral ring not
to sit into the groove.
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Page 6 of 9
CAUTION
DO NOT tolerate any leaks. Leaks can
result in corrosion and eventual
catastrophic vessel failure.
Replacing Elements
(contd.. )
When all the elements are fully inserted into the
vessel, install the upstream head with the adapter
fitted if required, as described in paragraphs 4
through 6 on page 5.
11. Reconnect piping to vessel as described in Remaking
Pipe Connection to Eng Plug on page 9.
Retaining ring seated in the grooove
7. Lubricate element seals sparingly with the element
manufacturers recommended lubricant or with
glycerine.
12. Pressurize the vessel. Inspect for leaks at connections
to the vessel and all around the vessel itself. If any
leaks occur, release pressure from the vessel and
tighten the fittings as necessary. Then pressurize
vessel and check for leaks again.
8. Insert each element with the brine seal (typically a
U-cup seat) installed on the upstream end with its
lip facing upstream.
CAUTION
System malfunctions and element damage
may result if elements are
installed in the wrong direction.
9. Install the interconnectors between multiple elements
as each succeeding element is installed.
NOTE
On some systems it may be easier to install
the piping connections before the he ad
is installed.
If so, please proceed with Steps 10 & 11.
10. Push each element downstream into the shell as it
is
installed until the element is fully engaged with the
downstream head. If the elements are hard to push,
make sure the brine seal is properly installed and you
are pushing from the upstream end.
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Page 7 of 9
Head
Disassembly
NOTE
Head Rebuilding should be performed in
a clean work area. Dust or dirt on O-rings
or other parts can scratch inner surfaces,
with subsequent l eakage.
1. Using a small screwdriver or similar tool remove
the Plug Seal. However do not damage the sealing
surface in any way as it may lead to leakage.
2. Using a small screwdriver or similar tool remove
the PWT Seal from the groove in the end plug.
Removal of the Plug Seal Removal of the PWT Seal
Head
Component Identification - Head Disassembled
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Page
8
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Head
Assem bly
1. Use only head components in as-new condition. Use
new O-rings each time the head is assembled.
4. Insert the Head Seal O-ring into the groove on
the outside diameter of the End Plug.
2. Cover O-rings with a this even layer of Parker Super
O-LubeTM silicon lubricant or the lubricant recomm-
ended by your element supplier.
Installing Plug Seal
5. Protect heads from contamination until ready
to assemble into the vessel(s).
Lubricating Plug seals and O-rings
NOTE
lycerine is a commercially avai
lable
lubricant that will not foul elemen ts.
However, silicon lubricant is
recommended for this applicat ion.
3. Assembly the Adapter Seal into the groove in the
End Plug.
Installing PWT Seal
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Page
9
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Refurbishing Parts
Inspecting Parts
Plastic parts: examine for cracking, softening or
discoloring. This may indicate chemical attack of the
material. Defective parts must be replaced. Alternate
material may be required. Contact your supplier or
Pentair Water for assistance.
Metal parts: check for corrosion, scratches, dents,
cracks or other damages to insert ring and spiral
retaining ring.
Other parts: examine for any damage, such as
gouges, chips or cracks, that could affect structural
strength or sealing characteristics. The following are
some examples of defects that may require replace-
ment of the affected part.
End Plug: crac ked, disc olor ed, seal ing
areas damaged(chipped or gouged), threads
stripped or cross-threaded.
Spiral Retaining rings: are the sole means of
end plug retention. Parts bent, corroded,
cracked or damaged in any way must not be
used. Carefully check for hairline cracks.
Refurbishing Other Part s
1. Remove any large deposits from metal parts
using a wire brush.
2. Scrub the entire surface with medium grade
ScotchBrite
T M
until all contaminants are removed.
3. Rinse parts clean with fresh water and dry.
4. Inspect all parts for serviceability as specified
above.
Remaking Pipe Connectio ns
to End Plug
1. Use a wire brush to remove all foreign matter
from threads on pipe fittings.
2. Apply non-hardening thread sealant or Teflon
TM
tape to fitting and install into end plug. Tighten each
fitting a maximum one quarter-turn past hand
tight; the plastic end plug could be
damaged if
fittings are over-tightened.
3. Fit end plug and retaining ring as described in
Replacing the Elements section on page 5 and 6.
Part Replac ement
Refurbishing Shell
1. Using a fine wire brush, remove any large
deposits from locking ring groove in the shell.
2. Using a medium or finer grade of ScotchBrite
TM
and mild soap solution, clean the inside of the
vessel at least 4 inches in from each end.
3. Use clean water to rinse away all loosened
deposits and soap residue.
4. Examine inside of vessel for
scratches, gouges,
or other imperfections that could prevent proper
sealing. If such areas exist and leaks are observed
when the vessel is placed back in service , the
shell may need to be replaced.
Replace all parts that cannot be restored to as-new
condition.
Replace any parts showing signs of structural
damage or corrosion.
CAUTION
Use of components damaged by corrosion
can cause catastrophic failure.
Seals should be replaced as necessary each time the
vessel is serviced. Any parts that need to be replaced
a r e a va i l a bl e f r om yo ur s uppl i e r or f r om
Pentair Water.
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