OPERATION AND MAINTENCE MANUAL

FOR
WATER AND STEAM SAMPLING SYSTEM
FOR
Indonesia ISM Power Plant

ENT KOREA
 TABLE OF CONTENTS

1. Preventive Maintenance for Sample conditioning rack

2. Preventive Maintenance for liquid analyzers

3. Maintenance for liquid analyzers

3.1 pH analyzer
3.2 Conductivity analyzer
3.3 Dissolved oxygen analyzer
3.4 Silica analyzer
3.5 Sodium analyzer
3.6 Hydrazine analyzer

4. Calibration procedure for liquid analyzers

4.1 pH analyzer
4.2 Dissolved oxygen analyzer
4.3 Silica analyzer
4.4 Sodium analyzer
4.5 Hydrazine analyzer
1. Preventive Maintenance for Sample conditioning rack

Maintenance
Items to be inspected Actions
Period
Daily Plant cooling water temperature - Check whether cooling water supply
(<40℃) an) and Pressure (3~ 6 system is normal.
㎏/㎠) In case of the abnormal condition persists,
Check point: Cooling water consult with
supply Press. & Temp. Indicator person(s) in charge to decide whether
(ex: CP501 / CT501) sampling system
have to be shut down until problem clears.
- Check whether instruments work properly.
Daily Final sample temperature - Check plant cooling water temp..
After cooler(s) below the 40℃ - Check for cooler leakage.
Check point: Temp. Indicator for - Confirm instrument work properly.
each sample line (ex:CT501) - Isolate in the sample line for repair in case
temp.
increase above 30℃
Daily Final sample pressure - Check pressure reducing valve and
After cooler(s) should be pressure relief valve
1 ~ 2 ㎏/㎠ for proper functioning.
Check point: Press. Indicator for - Check for any leakage from tube fittings,
each sample line (ex:CP501) valves, cooler, etc
- Confirm instrument work properly.
- Check for filter blockage, clean filter with
air or water.
If found out
Daily Check the cation exchanger In case of resin changed its color,
(resin) change from purple Regenerate the resin or refill by following
to yellow procedure
Regeneration procedure
Check point: Cation exchanger pour resin in column and fill it with
resin for each Cation approx.10% HCL solution
conductivity line When color of the resin is changed back to
purple.
 Drain HCL solution and wash resin with
demi. Water
If above regenerating procedure does not
work, discard
Old resin and refill with new one.

Daily Check resin column whether

Remove air bubble by varying flow to
It contains air bubble.
column and other
Check point: Cation exchanger
appropriate measures.
Resin for each cation
conductivity line
2. Preventive Maintenance for liquid analyzers

Maintenance
Items to be inspected Actions
Period
PH analyzer If necessary, refill or change KCL-
Weekly - Check sample flow solution(3.5 mol)
Weekly - Check level in electrolyte If necessary, open cap of pH electrode
(KCL-solution, 3.5 mol) slightly and let flow-
Check point: KCL-Bottle for each Out 2~3ml of electrolyte. Fasten cap hand-
pH electrode tight.

Conductivity analyzer(SC/CC) Clean electrode with a soft tissue and demi.

Yearly - Clean electrode with soft Water
Tissue and demi. Water In case of heavy contamination, dip the tip
of the sensor into
5% hydrochloric acid(HCL) for a short time.

!! Do not forget to rinse the sensor with

clean water!!
Dissolved Oxygen analyzer Refer to “Filling and membrane exchange”
Yearly - exchange the new sensor cap
& electrolyte

Silica analyzer If less than 1/6 is left, fill up with new

Weekly - Check sample flow reagent.
Weekly - Check level in the reagent Refer to :”Reagent Preparation”
containers If necessary, prepare new standard
Weekly - Check level of standard solution.
solution. Refer to :”Standard Preparation”

Sodium & Hydrazine analyzer If necessary, refill or

Weekly - Check sample flow change Diisopropylamine
Weekly - Check level in reagent bottle
(Diisopropylamine)
3.1 Maintenance for pH analyzer

- Maintenance schedule

Weekly Check level in electrolyte(KCl, 3.5Molar) bottle, if necessary

change bottle.
Monthly Calibrate electrode.
All 3 months Open cap of electrode slightly and let flow out 3~5ml of
electrolyte. Fasten cap hand-tight.

- Cleaning of electrode

If necessary, wipe the green tip of the electrode cautiously with a soft clean,
and damp paper tissue. If necessary, remove grease with a tissue, moisture
with alcohol (Caution! Inflammable!). Do not insert into acids.

- Longer stop of operation

Step1- Stop sample flow

Step2- Shut off power of the instrument.
Step3- Take off the cable of the pH electrode. and take the electrode out of the
Flow cell/fitting and rinse with clean water. fill 3.5 molar KCl(if not available:
water) into bottle and place it on the tip of the electrode. Never electrode dry!
Store the electrode with tip pointing downwards in a frost-protected room.
3.2 Maintenance for Conductivity analyzer

- Maintenance schedule

Weekly Check sample flow.

Yearly Cleaning of the sensor
Refer to “Cleaning of sensor”

- Cleaning of sensor
If the sensor is contaminated. Clean it with soapy water and a pipe cleaner. If
necessary, dip the tip of the sensor into 5% hydrochloric acid for approximately
30 seconds. After cleaned, please, rinsed of sensor with demineralized water
5 to 10 minutes.

- Maintenance of the cation exchange resin

The resin of the ion exchanger changes its color from purple to yellow if the
capacity is exhausted. Regenerate of the resin or refill as following;
Step1 – Stop sample flow.
Step2 – Take the resin column bottle out of the tubes/fitting(in/out tubes).
Step3 – Treatment of the ion exchanger with about 10% hydrochloric acid.
Step4 – If the ion exchanger changes its color from yellow to purple
Step5 – Rinsed of the ion exchanger with demineralized water 1 to 2 hours.

- Longer stop of operation

Step1- Stop sample flow

Step2- Shut off power of the instrument.
3.3 Maintenance for Dissolved oxygen analyzer

- Maintenance schedule

Weekly Check sample flow

Monthly Calibrate electrode.
Half a year Clean the electrode membrane with a soft tissue.
All 3 months Replace the electrode membrane and filling electrolyte.
Please, refer to “Filling and membrane exchange”

- Filling and membrane exchange

Step 1 – Switch of power of the instrument
Step 2 – Screw off the sensor cap, Exhaust the remaining electrolyte.

Step3 – Take the screw cap of the replacement kit (A-87.290.050) and fill it
completely with fresh electrolyte.
Step4 – There is a groove in the electrode thread, where excessive air and
electrolyte can escape while mounting the sensor cap. Hold the sensor in
Upright position, sensor tip pointing downwards with the groove on the upper
side.
Step5 – slowly fix the electrode head and the sensor cap to allow the excess
Electrolyte to escape without building up to much pressure inside the electrode.
Fasten sensor cap finger-tight.
Step6 – Clean the electrode thoroughly and dry the sensing membrane with
Soft tissue. And switch on power. Let the sensor run-in at air for at least 1 hour
Afterwards perform an air calibration. And reinstalled the sensor into the flow
cell.
- Longer stop of operation

Step1- Stop sample flow

Step2- Shut off power of the instrument.
Step3- To take the sensor out of the flow cell, turn the fastening of the sensor
counter clockwise. Unscrew it completely. And its take in the protected cap with
clean water. Never sensor dry!.
3.3 Maintenance for Silica analyzer

- Maintenance schedule

Weekly or after Run a standard calibration

change of Please refer to “Calibration procedure for silica analyzer”
reagents
Weekly Check reagent level
If less than 1/6 is left. Fill up the with new reagents.
Please refer to “Reagent preparation”
Yearly Exchange reagent pump tube(A-86.190.010)

- Reagent preparation
Warning:
1. Prepare the reagents with the best silica free DI water quality available.
Otherwise the measuring values are falsified.
2. All bottles are marked with the chemical name, appropriate danger symbol
and international safety code numbers. Always wear safety goggles when
handling strong acids.

Step1 – Rinse all containers well with demineralized water.

Step2 – Fill the container to 3/4 of its final level with demineralized water.
Step3 – Carefully add the chemicals.
Step4 – Screw the cover onto the container and mix well
Step5 – Fill the container to its final level and mix again.
Step6 – Put container into the holder, number 1 to 4 from left to right.
Step7 – Insert suction lancer/level detector into the container, make sure that
The number on the lances corresponds to the numbers on the containers.
Step8 – Lock cover.
Consist of reagent kit(A-85.420.560 / 3 packages)
- Reagent 1: Ammoniummolybdate
Reagent1a: Sodium hydroxide pellets, 15 g
Reagen1b: Ammonium molydate Tetrahydrate, 56 g

- Reagent 2: Sulfuric acid 25%, 200ml

- Reagent 3: Oxalic acid, Oxalic acid Dihydrate, 40 g

- Reagent 4: Ammonium Ferrous Sulfate

Reagen4a: Sulfuric acid 25%, 80ml
Reagent4b: Ammonium ferrous sulfate Hexahydrate, 26 g

- Longer stop of operation

Stop operation before maintenance
- Stop sample flow
- Shut off power of the instrument.
Step1 – Put suction lances into a bucket with demineralized water.
Step2 – Start fill system
Step3 – Wait until the peristaltic pump has stopped.
Step4 – Stop sample flow.
Step5 – Wait until the constant head is empty.
Step6 – Put suction lances into an empty bucket.
Step7 – Shut off power of the instrument.

- Restarting Normal operation

Step1 – Prepare reagents please refer to the “Reagent preparation”
Step2 – Insert suction lancer/level detectors.
Step3 – Turn on the sample flow and wait until the flow cell is completely filled.
Step4 – Switch on power (The system is filled automatically)
Step5 – Let the instrument run continuously for 1 hour.
Attention:
Do not establish sample flow before the pump tubes are activated.
3.5 Maintenance for Sodium analyzer

- Maintenance schedule

Weekly or Check for regular bubble formation.

every 2 weeks Check level of reagent bottle
Check level of KCl reservoir
Monthly Check sealing of reagent bottle, replace if necessary
Every Make a two-point calibrartion
3~6 months Make a pH measurement and correct value if necessary.
After long time Check if reagent(DIPA) is empty
Operation Check if reaction tube in clean

- Cleaning of electrode

- Sodium electrode: Only use the original etching solution from SWAN.
The etching solution is delivered in two bottles, one containing the acidic
solvent, the other containing the fluoride salt. Dissolve the salt in the
solvent before use and mark the date of mixing.
Rinse the electrode with ditilled water if etching the electrode for the first
time, insert the electrode for 2 minutes into the etching solution.
Rinse the electrode with distilled water.
Do not dry the sensing glass bulb!

- Reference electrode:
Step1 – Remove any ion deposits with a soft paper tissue.
Step2 – Slip the grounded glass sleeve upwards with a turning and pushing
movement, let about 1ml KCl flow out, and fix sleeve finger tight with a
gentle turning and pulling movement.
Replace or refill KCl reservoir. Use only original SWAN KCl.

- pH electrode:
Step1 – Remove any ion deposits with a soft paper tissue.
Step2 – Rinse the electrode with distilled water, Insert the electrode into the
etching solution for 2 minutes.
- Longer stop of operation

Step1- Stop sample flow

Step2- Dismount reagent bottle and close it firmly.(wait until the reagent empty
error)
Step3- Shut off power of the instrument.

- Restarting Normal operation

Step1 – Turn on the sample flow and wait until the flow cell is completely filled.
Step2 – Mount reagent bottle
Step3 – Switch on power.
3.6 Maintenance for Hydrazine analyzer

- Maintenance schedule

Weekly Check sample supply for dirt.

Check sample flow
Monthly Exchange DIPA if there is less than 150ml
Yearly Exchange diffusion tubes

- Disconnecting & Cleaning of electrode

- Hydrazine Sensor:
After cleaning, the sensor is very sensitive. Do not correct the value
Let the instrument run in for at least 24 hour.
Disconnecting:
Step1: Shut down the instrument
described see attached the “Stop
operation before maintenance”
Step2: Take off the sensor cable and put it
To the side to prevent wetting it.
Step3: Unscrew the two white knurled
fastening screws.
Step4: Take the hydrazine sensor out of
the flow cell.
Cleaning:
Step1: Take of the rotor.
Step2: Clean the two orifices with a pipe cleaner or a toothpick.
Step3: Clean the rotor with a pipe cleaner. Wipe the sensor with a soft
Tissue, mainly the platinum parts and the whole area which is in contact
With water.
Step4: Rinse all parts thoroughly with clean water.
Step5: Put rotor on the sensor.
Step6: Mount sensor, Fasten screws hand-tight
Step7: Connect sensor cable.
Step8: Open sample flow
 Step9: As soon as the rotor in turning, switch on power.

- Longer stop of operation

Step1- Shut down the instrument described see attached the “Stop operation
before maintenance”
Step2- Switch off power of all connected devices.
Step3- Remove filter vessel, empty, and remount
Step4- Dismount the reference electrode (please do not dry of the electrode)
Step5- Remove cable from the hydrazine sensor. Dismount sensor, dry it with
A soft, clean tissue, and store dry.

- Restarting Normal operation

Step1 – Turn on the sample flow and wait until the flow cell is completely filled.
Step2 – Mount reagent bottle
Step3 – Switch on power.
4.1 Calibration Procedure for pH Analyzer

Preparing of Standard calibration buffer No.7, No.9

Go to the choose menu 3.1.3(Standard pH).

Take the electrode out

of the flow cell

Rinse and dry electrode and put it into standard

1(=pH No.7)

Standard1, current value (Progress is shown)

Rinse and dry electrode and put it into standard

2(=pH No.9)

Standard2, current value (Progress is shown)

Calibration successful is shown

Rinse and dry electrode

and put it into the flow cell.
4.2 Calibration Procedure for Dissolved Oxygen Analyzer

Go to the choose menu 3.1. (Calibration).

Close regulation valve to turn off sample flow

Take the electrode out of the flow cell

and dry the electrode’s body and membrane
with a soft paper tissue.

Place the electrode into the wet flow cell at a

slightly titled angle

Saturation, sat. current value (Progress is shown)

Calibration successful is shown

Remount the electrode and

open the regulating valve.
4.3 Calibration Procedure for Silica Analyzer

Preparing of Standard solution 100ppb

Go to the choose menu 3.1

(Maintenance/Calibration).

Press<Enter> to save the value

In the calibration history
or leave the menu with <Exit>
4.4 Calibration Procedure for pH Analyzer

Preparing of Standard calibration 200 ppb & 2,000 ppb

Go to the choose menu 3.1.1(Standard Sodium).

Unmount electrode and rinse in deionized water

Etch sodium electrode for 30 seconds and rinse well

Mount electrode and wait 2-3 minutes

Screw standard bottle 1 onto the holder and

swing bottle upwards

Wait unit the process has

finished

First, press<Enter> to save. Then remove bottle

Press<Enter>for 2-point calibration

or <Exit> if you only want to make
a one-point calibration
4.5 Calibration Procedure for Hydrazine Analyzer

Compared Grab sample test before calibration

Go to the choose menu 3.1 .2

(Maintenance/Process Hydrazine).

Press<Enter> to save the value