Calibration and maintenance of ETPQMS

The Procedure is intended to provide guidance and instructions for carrying out the Calibration and maintenance of ETPQMS as per standard practices prescribed by OEM or General Industry best practices in safe manner while ensuring minimization of environmental impacts to the extent possible.

WORK INSTRUCTION:

ETQMS system provides comprehensive, monitoring, display, alarming, calculation, data logging, and data display, data storage, transmitting online data to CPCB & SPCB etc. for COD, BOD, and TSS & PH.

CONFIGURATION:

Fig 1: ETQMS configuration Drawing

     

The Real Spectrum GL2000 series is a continuous multiple wavelength UV absorbance testing analyzer which utilizes Real Tech Inc.’s Split-Sense Pro technology.

Main Component of ETQMS Analyzer:

a) Flow Cell

b) Xenon Lamp

c) Dehumidifier

Flow cell cleaning method:

A. Shut off the water supplies to the analyzer if not already done.

B. Disconnect the ¼” supply tubing at the influent connection on the analyzer.

C. Fill the wash bottle supplied with cleaning fluid and connect the ¼” bottle tubing to the influent connection on the analyzer.

D. Hold a finger over the small vent hole in the center of the wash bottle cap.

E. Squeeze the bottle to get the cleaning fluid to flow through the analyzer.

F. Once the fluid starts to flow remove finger from the vent hole and place bottle on top of analyzer as shown in Fig 6. The fluid should continue to flow through the analyzer. If it stops go back to step 4.

G. Let all the fluid run through the quartz flow cell until the bottle is empty.

H. Let the fluid remain in the quartz flow cell for several minutes until the quartz flow cell is clean.

I. Disconnect the hose and bottle from the fitting.

J. Connect the water supply line to the unit and open the valve to start the flow running.

Fig -2: Flow Cell cleaning Bottle & chemical used for cleaning.

UV Lamp Replacement:

A. The lifespan of the Xenon Lamp is rated for 3-5 years. Contact Real Tech Inc. or your supplier for a replacement lamp.

B. Lamp replacement is straight forward.

C. Disconnect the cable from the lamp.

D. The lamp/bracket assembly should be removed from the back plate as one piece. Simply remove the two shoulder bolts that attach the lamp bracket to the back plate.

E. Install the new lamp/bracket assembly using the two shoulder bolts.

F. Reconnect the cable to the lamp.

G. Re-calibration of the analyzer is required at this time.

Dehumidifier for Humidity Control:

A. The Real Spectrum GL2000 series includes a dehumidifier to control the humidity inside the analyzer.

B. It will maintain low relative humidity (RH) to prevent condensation from forming on the quartz flow cell walls.

C. The dehumidifier is designed to maintain low humidity inside the Real Spectrum Analyzer for 6-12 months before regeneration.

D. To regenerate simply remove the dehumidifier and plug into a 110 - 240 VAC wall outlet for 10-12 hours. The color bar on the front will turn dark blue.

E. When the dehumidifier is fully regenerated. There is no limit to the number of times the dehumidifier can be regenerated.

F. Each time the door to the cabinet is opened this drying process starts over, so it is recommended to keep the cabinet door closed as much as possible when in a high ambient humidity environment.

G. The humidity alarm is triggered if the humidity level is 25% RH or above.

CALIBRATION OF ANALYSER:

       

Zeroing (Calibration):

The analyzer must be initially zeroed before accurate data can be read. For best results, it is preferred to have the Real Spectrum Analyzer powered with door closed and lamp on for 15-30 minutes before performing the zeroing operation.

Before zeroing, remove the correlation from the database.

Fig -3: Fig for removing correlation of COD/BOD/TSS

Zeroing with DI water:

A. Shut off the water supply to the Real Spectrum Analyzer.

B. Disconnect the ¼” sample water supply tubing at the influent connection on the analyzer.

C. Fill the wash bottle supplied with DI water and connect the ¼” bottle tubing to the influent connection on the analyzer.

D. Hold a finger over the small vent hole in the center of the wash bottle cap.

E. Squeeze the bottle to get the DI water to flow

F. Through the analyzer.

G. Once the fluid starts to flow remove finger from the vent hole and place bottle on top of analyzer. The fluid should continue to flow through the analyzer. If it stops go back to step 4.

H. After the analyzer has been flushed press the “Zero” button located on the “Configuration” tab of the panel PC, making sure the correlated value in the calibration textbox is zero.

I. The Real Spectrum Analyzer will take 2 minutes to fully zero itself. Disconnect the wash bottle hose from the influent connection of the analyzer and reconnect the sample water supply tubing.

J. Open the valve to allow the sample water to flow.

After zeroing put the correlation back to the database by below process:

A. Save the correlation file in USB/hard disk.

B. Insert the pen drive in the HMI USB slot.

C. Click on Add correlation. Add correlation in sequence. First Add BOD, then COD, then TSSS.

D. Then click on upload correlation.                        

                                                                Fig-4 Removing correlation of COD/BOD/TSS

Fig 5: upload correlation Screen 01 

Select your file & click Add correlation.

Fig 6: upload correlation Screen 02

Normal checkup:

A. Water should come to analyzer through pump.

B. Pump provided with analyzer should always in running condition.

C. Online Data Transmission to CPCB & SPCB should be greater than 85%.

D. Clean all panel using vacuum cleaner. The vacuum cleaner must be kept at distance from the panel.

E. Check the input AC power supply. Check the tightness of all power cables.

F. Ensure the Exhaust fan must be in running condition.

CHECKS BEFORE RELEASE OF PERMIT:

A. All T & P’s and manpower are removed.

B. Clean the maintenance area properly.

C. Normalize all isolation & Return PTW

HANDLING OF CONCESSIONS OR DEVIATIONS:

A. In the Event of Any Changes or Deviation from Procedure are required due to Urgent business requirements or system/Equipment approval should be obtained from Head O&M.

B. The report for the concerned task should clearly Captured the details of deviations and reason for the same.