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The BioTector B7000i TOC analyzer with integrated oxygen concentrator
Process Tests
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BioTector Documents This presentation should be viewed with the following document available: Manual appropriate to the BioTector B7000i Note that this presentation covers a typical system, your system may incorporate slight changes not shown in this presentation.
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Safety Wear appropriate PPE!
The BioTector runs on mains electricity, 115V or 230V Some components may be hot The BioTector uses acidic and basic reagents Electrostatic devices may be present on some PCB’s, always wear a grounding strap
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Process Test Procedures
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Pressure Test Purpose: Frequency of activation: Operation: Note:
To detect a leak or partial leak in the BioTector Frequency of activation: Once per day, and when the BioTector analyzer is started Operation: The microcontroller activates the MFC with a gas flow of 40 LPH If there is no leak in the BioTector, the gas flow will drop eventually to 0 LPH If the gas flow drops below 4 LPH (default Pressure Test Warning setting) within 60 seconds, the pressure test passes If the gas flow is above 4 LPH but below 6LPH (default Pressure Test fault setting), a pressure test warning is logged If the gas flow remains above 6 LPH at the end of the pressure test, then the pressure test fails, a fault is logged and the BioTector stops Note: 1: In addition to the Pressure Test detailed above which operates once per day and each time the BioTector is started, a Pressure Check is carried out as part of the Reactor Purge sequence. The Pressure Check only has pass /fail settings, it cannot generate any warning of a small leak in the BioTector. The default setting is 6 LPH. 2: Pressure Tests are carried out at 400mbar, while the BioTector runs typically at 4mbar, making the Pressure Tests a sensitive leak detection system
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Typical Pressure Test Menu
T 9 : 1 7 2 8 - < * I Z A C O M 6 s F N 4 . l / h L W 3 G B H Two modes available: Pressure Test - Simulate the pressure test using the same time the BioTector allows (60s) Pressurize Reactor - Simulate the pressure test with long time limit, useful for detecting a leak
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Pressure Test Examples of some potential leak points in the B7000i.
Valve leaking? Ozone Generator Air Pressure correct? MV1 Exhaust EXHAUST Air Cooler CO2 Analyser Oз Destructor AIR Oxidized Fluid Catch-pot SAMPLE OUT Leak in analyzer? MFC reading correctly? Sample in (ARS) valve leaking, (around valve ball into the sample drain line)? MV3 Cleaning MV7 Injection BYPASS MV11 Stream 2 MV9 Manual MFC MV4 Sample In STREAM 1 STREAM 2 P1 Sample Pump MANUAL OXYGEN O2 Pressure correct? MV6 Acid Oxygen module ACID Mixer P2 P3 Acid Pump Pump leaking? Mixer Reactor leaking through diaphragm? BASE P4 Base Pump Valve leaking? Reactor MV5 Sample Out Fitting leaking? Examples of some potential leak points in the B7000i.
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Structured Fault Finding
Pressure Test: Structured Fault Finding 6. Seal exhaust valve. Test. Ozone Generator 1. Is the air pressure correct? MV1 Exhaust EXHAUST Air Cooler CO2 Analyser Oз Destructor AIR Oxidized Fluid Catch-pot SAMPLE OUT 3. Is the MFC reading correctly? MV3 Cleaning MV7 Injection BYPASS MV11 Stream 2 MV9 Manual MFC MV4 Sample In STREAM 1 STREAM 2 P1 Sample Pump MANUAL OXYGEN 2. Is the O2 pressure correct? MV6 Acid Oxygen module ACID Mixer P2 P3 Acid Pump 5. Disconnect cooler outlet tube. Seal cooler tube. Seal sample out valve. Test. BASE 4. Disconnect Ozone outlet tube. Seal ozone outlet. Test. P4 Base Pump Reactor MV5 Sample Out Examples of some potential leak points in the B7000i.
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Flow Test Purpose: Frequency of activation: Operation: Note:
To detect a blockage or partial blockage in a gas flow path BioTector Frequency of activation: - Once per day, and when the BioTector is started Operation: - The microcontroller activates the MFC with a gas flow of 60 LPH - The gas flow through the exhaust and sample out valves / lines are tested independently - If there is no blockage in either of the lines, and the BioTectors flow remains above 45 LPH (default flow warning setting), the flow test passes - If the gas flow drops below 45 LPH but remains above 30 LPH (fixed Low O2 Flow fault setting) within the 30 second flow test time, a flow warning is logged - If the gas flow drops below 30LPH, a flow fault is logged and the BioTector stops Note: In addition to the Flow Test detailed above which operates once per day and each time the BioTector is started, the gas flow is continuously monitored as the analyzer runs. If the flow falls below 50% of its set-point for >12 seconds, a fault is generated and the BioTector stops
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Typical Flow Test Menu Two modes available for each valve:
T E S 9 : 1 7 2 8 - < * X H A U 3 M P 4 I s C N 6 . l / h 5 G R B Two modes available for each valve: Exhaust (or Sample Out) Test: Simulate the flow test using the same time the BioTector allows (30s) Exhaust (or Sample Out) Flow: Simulate the flow test with long time limit, useful for detecting a blockage
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Oxygen inlet to reactor blocked?
Flow Test: Exhaust Line blocked outside BioTector? Ozone Generator Valve blocked? Air Pressure correct? MV1 Exhaust Ozone destructor filter blocked? EXHAUST Air Cooler CO2 Analyser Oз Destructor AIR Oxidized Fluid Catch-pot SAMPLE OUT MFC reading correctly? MV3 Cleaning MV7 Injection BYPASS MV11 Stream 2 MV9 Manual MFC MV4 Sample In STREAM 1 STREAM 2 P1 Sample Pump MANUAL OXYGEN O2 Pressure correct? MV6 Acid Oxygen module ACID Mixer P2 P3 Acid Pump Oxygen inlet to reactor blocked? BASE P4 Base Pump Reactor MV5 Sample Out Above are some examples of some potential blockage points in the BioTector Note that the Exhaust valve and Sample out valve lines are tested independently. Always follow a structured approach when looking for a blockage in a tube. CAUTION: Traces of chemicals may be in tubes when they are opened
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Flow Test: Exhaust 5. Disconnect tube after ozone destructor. Test. 6. Disconnect tube outside BioTector. Test. Ozone Generator 1. Is the Air Pressure correct? MV1 Exhaust 7. Disconnect tube over cooler. Test. EXHAUST Air 4. Disconnect tube before ozone destructor. Test. Cooler CO2 Analyser Oз Destructor AIR Oxidized Fluid Catch-pot 3. Is the MFC reading correctly? Test only when system de-pressurized. SAMPLE OUT MV3 Cleaning MV7 Injection BYPASS MV11 Stream 2 MV9 Manual MFC MV4 Sample In STREAM 1 8. Disconnect tube at TEE, but only when system de-pressurized. Test. STREAM 2 P1 Sample Pump MANUAL OXYGEN 2. Is the O2 Pressure correct? MV6 Acid Oxygen module ACID Mixer P2 P3 Acid Pump BASE P4 Base Pump Reactor MV5 Sample Out Always follow a structured approach when looking for a blockage Always allow 1 minute for each test, as oxygen gas will flow until the system is pressurized. CAUTION: Traces of chemicals may be in the tubes when they are opened.
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Flow Test: Sample Out Ozone Generator Air Pressure correct? MV1 Exhaust EXHAUST Air Line blocked outside BioTector? Cooler CO2 Analyser Oз Destructor AIR Oxidized Fluid Catch-pot Valve blocked? SAMPLE OUT MFC reading correctly? MV3 Cleaning MV7 Injection BYPASS MV11 Stream 2 MV9 Manual MFC MV4 Sample In STREAM 1 STREAM 2 P1 Sample Pump MANUAL OXYGEN O2 Pressure correct? MV6 Acid Oxygen module ACID Mixer P2 P3 Acid Pump Valve blocked? BASE P4 Base Pump Reactor MV5 Sample Out Above are some examples of some potential blockage points in the BioTector Note that the Exhaust valve and Sample out valve lines are tested independently. Always follow a structured approach when looking for a blockage in a tube. CAUTION: Traces of chemicals may be in tubes when they are opened
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Flow Test: Sample Out Ozone Generator 1. Is the Air Pressure correct? MV1 Exhaust EXHAUST Air Cooler CO2 Analyser Oз Destructor AIR Oxidized Fluid Catch-pot SAMPLE OUT 3. Is the MFC reading correctly? MV3 Cleaning MV7 Injection BYPASS 6. Disconnect sample out tube. Test. MV11 Stream 2 MV9 Manual MFC MV4 Sample In STREAM 1 4. Disconnect Ozone outlet tube, but only when system de-pressurized. Test. STREAM 2 P1 Sample Pump MANUAL OXYGEN 2. Is the O2 Pressure correct? MV6 Acid Oxygen module ACID Mixer P2 P3 Acid Pump 5. Disconnect Tube after the valve. Test. BASE P4 Base Pump Reactor MV5 Sample Out Always follow a structured approach when looking for a blockage Always allow 1 minute for each test, as oxygen gas will flow until the system is pressurized. CAUTION: Traces of chemicals may be in the tubes when they are opened.
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Ozone Test Purpose: Operation: Note:
To check the level of ozone generated by the BioTectors ozone generator The ozone test uses the procedure described in information sheet “T021. Procedure to check the ozone level in BioTector with Mixer Reactor” The user must read and understand the process described in this sheet, and have all the correct parts listed in this sheet before carrying out this test. Operation: When the test kit has been installed in accordance with T021 and the installation confirmed by the user, the BioTector activates the ozone generator The BioTector calculates Pass, Low Ozone or Fail against its programmed criteria. The user can also check the time required for the o-ring to break against the graph in T021. This provides an indication as to how well the ozone generator is operating Note: Always use a new o-ring for each test, and do not carryout the test with an o-ring which has been fitted to the test bar for some time. This o-ring will have stretched and so give a false result.
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Typical Ozone Generator Test Menu
When the ozone generator test has been installed in accordance with T021, the user activates the Start Test menu item When the o-ring breaks, the user activates the Stop Test menu item If the o-ring breaks within 18s (or programmed level), the status of the ozone test is Pass If the o-ring breaks in a time between 18 and 60s, the status of the ozone test is Low Ozone If the o-ring does not break within 60s, the status of the ozone test is Fail
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Only work on ozone generator if mains power is isolated
Ozone Generator Test Warning: Only work on ozone generator if mains power is isolated Ozone Generator MFC MV7 Injection Oxygen purity >93% oxygen, and free of water and oil? OXYGEN Mass Flow Controller Liquid In ozone generator? Coil resistance ok? If in doubt, replace it. Connections tight on coil? Connections tight on thermostat? Confirm connections are tight If PCB is suspected as being faulty, replace it.
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Sample Pump Test Purpose: Operation:
- To simulate the operation of the sample pump Operation: - The microcontroller turns the sample pump on in the forward or reverse direction - When running forward, the sample should be pumped out through the sample bypass port, and on for 1 additional meter, to ensure a fresh sample is injected - The sample should always be as near to the BioTector as possible, and always be at atmospheric pressure - When running in reverse, the sample should be pumped completely back to the sample point, and the sample line left empty - When the pump is stopped by the user or computer, the run time is displayed on the screen
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Typical Sample Pump Test Menu
The stream valve as well as the sample pump forward and reverse times can be checked When the correct time has been determined, the settings can be changed by following the link to the Sample Pump screen Different times are programmable for each stream or manual sample
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The sample should be pumped out the drain and on for 1 meter.
Sample Pump Test: Forward The sample should be pumped out the drain and on for 1 meter.
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Sample Pump Test: Reverse
Sample and oxidized fluid should be completely pumped back to sample point.
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pH Test Purpose: Operation:
- To check the pH in the reactor at different stages in the reaction The user must understand the procedure for testing the pH in the BioTector Use eye protection and gloves Have all the relevant parts for this test ready (primarily beaker and pH paper) before carrying out the test Operation: - The pH in the reactor is checked using the sample from the sample stream - The TIC acid reagent and sample are first injected into the reactor and mixed together, then the process stops allowing the pH to be checked - The process is repeated for the Base reagent and the TOC acid reagent
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Typical pH Test Menu Any range or sample stream can be checked, and any operating mode (for example, TIC&TOC or TC): When the fluid has been mixed in the reaction, the process stops to allow the user check the pH Only a very small sample should be removed from the reactor, so as not to effect the pH for the next test It is important that the previous reaction finished normally to eliminate the possibility of any pH influence from the previous reaction
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pH Test: Example TIC pH Test
Ozone Generator MV1 Exhaust EXHAUST Air Cooler CO2 Analyser Oз Destructor AIR Oxidized Fluid Catch-pot SAMPLE OUT MV3 Cleaning MV7 Injection BYPASS MV11 Stream 2 MV9 Manual MFC MV4 Sample In STREAM 1 STREAM 2 P1 Sample Pump MANUAL OXYGEN With the reactor mixer stopped, the liquid accumulates at the bottom of the reactor. MV6 Acid Oxygen module ACID Mixer P2 P3 Acid Pump BASE Open the fitting after the sample out valve, and activate the “Take Sample” function until the liquid drips out the valve. Note if too much liquid is used, then the complete test may have to be repeated to accurately test the next phase. P4 Base Pump MV5 Sample Out pH paper Reactor Above is an example of testing the pH in the TIC phase. The TIC acid reagent and sample are first injected into the reactor, and mixed with the reactor mixer. When the fluid has been mixed in the reaction, the process stops to allow the user check the pH. Only a very small sample should be removed from the reactor, so as not to effect the pH for the next test.
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pH Test: Commonly Found Issues
Ozone Generator MV1 Exhaust EXHAUST Air Cooler CO2 Analyser Oз Destructor AIR Oxidized Fluid Catch-pot SAMPLE OUT MV3 Cleaning MV7 Injection BYPASS MV11 Stream 2 MV9 Manual MFC MV4 Sample In STREAM 1 STREAM 2 Are the programmed settings for sample, acid and base correct? P1 Sample Pump MANUAL OXYGEN Is the pH in the sample very high ~>11pH or very low ~<3pH? MV6 Acid Oxygen module ACID Mixer P2 Acid, Base pump: pumped volume correct? P3 Acid Pump BASE P4 Base Pump MV5 Sample Out Acid, Base reagents: Is the normality correct? Reactor Reactor mixer mixing liquid? Here are shown some examples of where pH issues could occur
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Sample Valve Test Purpose 1: Reason: Purpose 2:
To ensure that the valves stops correctly with its magnetic sensor active. Reason: If the valve does not stop on its magnetic sensor, the sample pump will not run as it assumes the valve is closed with respect to the direction of liquid flowing in the tubes. Should this occur, a “Sample Valve Not Sync” fault will occur. Purpose 2: To ensure that the drilling in the ball of the valve lines up with the ports on the valve. If the drilling does not line up with the ports, then particles will accumulate which could block the valve, or reduce its life. Note: See additional details in Information Sheet “M046 Sample Valve Adjustment and Sample Tube Positioning Guidelines”.
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Typical Sample Valve Test Menu
V T 9 : 1 7 2 8 - < * F I R U N 3 D J , O C Y G B H The final “Adjust Sample Valve” settings should be 6 points or more below the “First Failure” point.
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