THERMO-SCIENTIFIC ORION PHOSPHATE ANALYZER (2295)

PURPOSE : The purpose of this document is to make understand the standard calibration and maintenance procedure of THERMO-SCIENTIFIC ORION PHOSPHATE Analyzer (2295) and according to this procedure, PHOSPHATE Analyzer will be calibrated as per the OEM recommendations for calibration and can help to maintain accuracy and reliability of readings.

SOURCE: USER MANUAL

GENERAL RESPONSIBILITIES:

               ·       Ensure work permit is available

·       Ensure that the Reagents Solutions are made as per the OEM. Reagents must be replaced at the time of calibration and confirm with chemist that all the solutions are mixed thoroughly before use.

·       Check for leaks, particularly around the sample and drain pipe work connections.

·       Confirm sample flow by checking delivery to the constant-head unit and effluent from the drain.

·       Check liquid levels in the reagent.

·       Inspect all tubing and liquid handling components for leaks and deterioration.

·       Check for malfunction indications on the analyzer display.

·       Ensure following PPE as per EHS procedure no. xxxxxxxxxxxxxxxxx Safety shoe, Helmet, Dust Respirator, and Protective Eye Wear and proper hand Wear.

·       Ensure Healthiness & Safety of the entire activities with respect electrical and Mechanical system. 

Job Specific Responsibilities:

Sl.No	Particulars	Responsibility
1	Issue and Closure of  work permit	Engineer in charge/ Operation unit & shift in charge
2	Ensuring isolation	Operation shift/unit in charge
3	Monitoring availability of required tools & tackles and implementation of relevant OH&S and Environmental Procedures	Engineer in charge/Supervisors
4	Checking the Quality of Job and Providing feedback to ensure task Completion as per the procedure	Engineer in charge
5	Performing of tasks in compliance with Instructions and safe working with Equipment	Technicians
6	Carrying out relevant monitoring tasks such measurement, verification and validation to ascertain completion of Scheduled tasks.	Engineer in charge

 

STARTUP PROCEDURE:

·        Power on instrument.

·        To allow longer lifetime of unit, the pump-head tubing are not fully engaged when the unit is shipped. Refer to Plumbing Connections Section.

·          Reset tubes in pumps heads.

         Note: This step must be repeated for all four pump heads.

i.           Remove tape.

ii. Slide tube retainer into place along keyway.

iii. Install tubing cover by squeezing both sides, and sliding into grooves.

Install Reagents. Very carefully match reagent numbers and colors in their proper order.

Prime the tubing. Please repeat the following sequence 3 times.

a. Press Menu.

b. Select Services.

c. Select Prime Fluidics.

d. Select Prime All.

 Note: This procedure will run automatically and take approximately 10 minutes per cycle.

·        Once the above 4 steps have been completed, (4. a, b, c, d) press Stop, Select Run. Allow the unit to operate overnight or for at least 12 hours, to become stabilized in the local environment.

GENERAL INSTRUCTION FOR USER INTERFACE COMPLIANCE:

·        The user-interface consists of a keypad and a graphical LCD display. The keypad is located to the right of the display. The "F1-F4" function keys (soft-keys) take on different meanings depending on the menu selection.

·        The column on the left of the soft-keys labels the keys with their appropriate functions.

·        The RUN key starts the analysis and the STOP key stops the current functioning of the

Instrument.

·        The + and - keys allow for navigation between pages.

·        The ENTER key confirms selections made in the menus. Additional navigation is provided by the soft-keys (in appropriate menus), for left / right or up / down cursor movement.

·        The graphical LCD display shows the date, analysis label, time, navigational menus, information and help to the user, current user, instrument-working mode, current status of the instrument and the soft-key labels.

·        The MENU key is used to access the menus.

Display Fields:

• DATE FIELD shows the current date.
• CURSOR indicates current selection.
• INSTRUMENT NAME FIELD shows instrument nametag.
• TIME FIELD shows present time.
• DISPLAY FIELD shows menus / measurements.
• INFO field shows information / instructions to navigate.
• USER field shows current user name.
• MODE field shows whether the instrument is working in Auto, Manual or Run mode.
• STATUS field shows current working status of the instrument.
• FUNCTIONAL KEYS ASSIGNMENT FIELD shows the functions allotted to the functional keys.
• FUNCTION KEYS select functions.
• OPERATIONAL KEYS are meant for operation of the instrument.

WORK INSTRUCTION PROCEDURE:

·        Check the tightness of all cable terminations & tube fittings.

·         Ensure healthiness of LCD & sensor.

·         If transmitter showing error/bad reading, sensor to be checked.

·         Before switching off the power supply, ensure transmitter display is working normally.

·         If transmitter showing error/bad reading.

·         Switch on the power supply

·         Reading in transmitter display should match with DCS.

THE WORKING PRINCIPLE:

·        The colorimetric method is based on the reaction of reagents with the sample to produce a color. This color is measured and compared to a standard color, which proportionally defines its concentration.

·        The color compound, which is the reacted mixture of the sample with the reagents, absorbs energy at a specific wavelength in accordance to Beer-Lambert Law.

 

4.3.1        DETAILS OF HAZARD INVOLVED:

·        Electric Shock.

·        Fire

·        Injury due to improper handling of Regents

·        Skin burning

·        These warnings identify areas of potential hazard, which could result in personal injury, or loss of life.

4.3.2        SAFETY PRECAUTION REQUIRED:

·        The Thermo Scientific 2295 Phosphate Analyzer has been designed with careful attention to safety. It complies with formal safety design rules established by international regulatory agencies. Observe all safety warnings marked on the instrument.

·        To ensure that the protection provided by this equipment is not impaired, do not use or install this equipment in any manner other than that which is specified in this manual.

·        Do not use this product for any purpose other than described in this manual.

·        Disconnect power before servicing and prior to making any terminal connections within the Analyzer enclosure.

·         Do not operate with the electronics enclosure door open.

·        Ensure proper ventilation at the work place

·        Ensure use of proper PPE’s

·        Keep the fire extinguishers (CO2 gas / DCP) ready within reachable limit for any exigency at the vicinity of work place.

·        Ensure proper Earthing &  proper illumination

·        Ensure proper range of multi meter & test probe for different measurement.

·        Insulated general tools to be used.

·        Ensure good housekeeping of maintenance site.

·        Permit Type: Permit to Work Order

·        Permit Approving Authority: Shift in-charge (Main Control Room).

SPARES & CONSUMABLES:

·        The Phosphate analysis requires two reagents.

·         The reagent usage depends on the frequency of analysis. Typically 0.23 mL of each reagent is used per analysis cycle.

·        Based on 4 analyses per hour, the 1 Liter reagents should last approximately 45 days.

 

Parts and Accessories

Catalog Number                                                                    Description
Maintenance and Service Items
2295MK	Maintenance Kit
2230PA	Pump Head Tubing Covers (3 each)
2230PS	Power Supply Assy
2230FS	Power Fuses
2295TK	Main Tubing Kit
2230BC	Empty Auto Cal Btl (Validation Sample Bottle)
2230SF	Fittings, Sample In, Sample Out and Drain
2230RC	Reagent and Standard Bottle Cap - includes fittings
Reagents and Standards
2295REC	Reagent
229510	10 ppm Calibration Standard (For calibration range 0.2-20 ppm)
229530	30 ppm Calibration Standard (For calibration range 20-40 ppm)
229550	50 ppm Calibration Standard (For calibration range 40-50 ppm)

 FREQUENCY OF MAINTENANCE

5      

Maintenance                                      Conduct regular maintenance Schedule Frequency                     to ensure the analyzer performs properly.
Every week	Inspect in / out tubes, reagent bottle, and all tubes for fouling.
Every month	Inspect tubing and ensure that it is not blocked.
Every 1.5 months	Replace reagent if necessary every 45 days.
Every 12 months	Replace pump tubing. Use factory supplied maintenance kit. Inspect for any fouling of the reaction cell.

 

ISOLATION PROCEDURE:

·           To put the System in Stand-by mode, make sure to press the STOP key and check the DISPLAY field next to F4 to show MANUAL RESTART. If AUTO RESTART is selected, you need to set the mode to Manual:

·        MENU ➔ SETUP ➔ + ANALYSIS PARAMETERS ➔ MODE

·        The system will switch to Stand-By after 60 minutes of no keypad activity. In Stand-By, the analyser will rotate the pumps periodically to avoid pinched tubing from sealing.

·        To avoid clogging, flush the entire system with distilled water before shutdown. Disconnect and empty out the reagents bottles and flush the lines using FLUIDICS PRIME menu. Release the pressure on the peristaltic pump tubing.

·        Use the table below to diagnose and correct analyzer problems.

T&P INCLUDING SPECIAL ONES

·        Multi meter

·        General tools.

·        Tissue paper.

·        DM Water

CALIBRATION:

 ·        Executing a Manual Calibration:

·        If the result is outside the user specified tolerance (default 5%), the analyzer will warn the user to avoid storing the wrong calibration data. The user may then ACCEPT or REJECT the calibration result.

·         Note user accepted manual calibration will become the REFERENCE calibration data.

·        The analyzer will use the REFERENCE calibration data when checking for the acceptable

·        Tolerance limits in BOTH manual and auto Cal cycles. gee of using this function over the Run Analysis function is that prior knowledge of the concentration allows for validating the accuracy of the analyzer, without affecting the data reporting to your control center or device.

In Auto-Calibration Mode:

·        The system will run a second calibration cycle if the first calibration result was outside the user specified tolerance.

·         If the second calibration result is still outside the specified tolerance limits,

·        The analyzer will continue to use the previously stored calibration and will flash the “CHK CAL” message in the Info section of the LCD screen.

·        The “CHK CAL” message can be cleared by resetting the fault alarm under VIEW DATA AND ALARMS ➔ REVIEW/RESET ALARMS or by running a manual    calibration.

·        The result of the calibration will be displayed as follows:

·        STANDARD : 10 ppm ***depends on the range selected

·        ABSORBANCE : 0.19

·        SLOPE : +055.00

·        INTERCEPT : -0.4

 NOTES:

·         Running a validation is identical to running an analysis: Although the results are printed they are not stored, alarm conditions are not tested, and the analog outputs are not updated.

·        It is highly recommended to allow the Orion 2295 Phosphate Analyser to complete its measurement cycle rather than using the STOP key.

·        If the STOP key is pressed before a measurement cycle is complete, it is highly recommended to perform both the AUTO PRIME ALL and CLEAN sequences.

Cleaning

·        Automatic flushing of the reaction cell may be programmed. The default setup for the analyser uses the sample as the cleaning solution. A cleaning cycle can be performed by pressing:

·        STOP ➔ MENU ➔ MEASUREMENT ➔ CLEAN

·        This cycle helps maintain clean reaction cell.

NOTE:  To avoid damage and contamination to the reaction cell, use only cleaning solutions recommended by the factory.

Post Wash:

·        Automatic post wash cycles are typically part of every measurement cycle. At the end of the analysis, the post wash cycle evacuates the reacted sample from the cell and cleans it to minimize coating and residue deposits in the cell. The post wash cycle settings can be accessed from the ANALYSIS PARAMETERS menu:

                  MENU ➔ SETUP ➔ (+) ANALYSIS PARAMETERS ➔ (+)

                  Please consult factory before modifying any of the parameters.

Priming:

·        Priming of the instrument lines may be done as auto (all the solutions) or manually by selecting the specific reagent or standard. Priming fills the tubing, purges the lines of air, and prepares the analyzer for measurement mode.

·        The PRIME VOLUME in mL applies to all the listed solutions in the priming menu.

·        The Prime Volume may be specified as a (-) number; this allows the user to pump back the reagents inside the tubing back into the reagents containers allowing for safer service when replacement of the tubing is needed. User may select to pull back all or any one of the reagents or standard.

 CHECKS BEFORE RELEASE OF PERMIT

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

·        Clean the maintenance area properly.

·        Normalize all isolation  & Return PTW

 

HANDLING OF CONCESSIONS OR DEVIATIONS: 

·        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.

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

 

 

5                 REFERENCES:

THERMO-SCIENTIFIC ORION PHOSPHATE (2295)