The Bio Tector B 7000 i TOC analyzer

The Bio. Tector B 7000 i TOC analyzer with integrated oxygen concentrator Process Tests

Bio. Tector Documents This presentation should be viewed with the following document available: • Manual appropriate to the Bio. Tector B 7000 i Note that this presentation covers a typical system, your system may incorporate slight changes not shown in this presentation.

Safety • Wear appropriate PPE! • The Bio. Tector runs on mains electricity, 115 V or 230 V • Some components may be hot • The Bio. Tector uses acidic and basic reagents • Electrostatic devices may be present on some PCB’s, always wear a grounding strap

PROCESS TEST PROCEDURES

Pressure Test • Purpose: – To detect a leak or partial leak in the Bio. Tector • Frequency of activation: – Once per day, and when the Bio. Tector analyzer is started • Operation: – – – The microcontroller activates the MFC with a gas flow of 40 LPH If there is no leak in the Bio. Tector, 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 6 LPH (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 Bio. Tector stops Note: 1: In addition to the Pressure Test detailed above which operates once per day and each time the Bio. Tector 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 Bio. Tector. The default setting is 6 LPH. 2: Pressure Tests are carried out at 400 mbar, while the Bio. Tector runs typically at 4 mbar, making the Pressure Tests a sensitive leak detection system

Typical Pressure Test Menu P R E S S U R E T E S T 0 9 : 1 7 : 2 8 1 2 - 0 9 - 0 2 1 < * P R E S S U R E T E S T 2 P R E S S U R I Z E R E A C T O R T I M E 6 0 s M F C S E T P O I N T 4 0 . 0 l / h M F C F L O W 0 3 . 3 l / h S T A T U S T E S T I N G P R E S S E S C T O A B O R T T H E T E S T Two modes available: • Pressure Test - Simulate the pressure test using the same time the Bio. Tector allows (60 s) • Pressurize Reactor - Simulate the pressure test with long time limit, useful for detecting a leak

Pressure Test Valve leaking? Ozone Generator Air Pressure correct? MV 1 Exhaust EXHAUST CO 2 Analyser Cooler AIR Oз Destructor Air Oxidized Fluid Catch-pot SAMPLE OUT Leak in analyzer? MFC reading correctly? MV 7 Injection Sample in (ARS) valve leaking, (around valve ball into the sample drain line)? MV 3 Cleaning MFC BYPASS MV 9 Manual STREAM 1 MV 4 Sample In OXYGEN MV 11 Stream 2 STREAM 2 P 1 Sample Pump MANUAL O 2 Pressure correct? MV 6 Acid Oxygen module ACID Mixer P 3 Acid Pump P 2 Mixer Reactor leaking through diaphragm? Pump leaking? BASE P 4 Base Pump Valve leaking? Reactor Fitting leaking? MV 5 Sample Out Examples of some potential leak points in the B 7000 i.

Pressure Test: Structured Fault Finding 6. Seal exhaust valve. Test. Ozone Generator 1. Is the air pressure correct? MV 1 Exhaust EXHAUST CO 2 Analyser Cooler AIR Oз Destructor Air Oxidized Fluid Catch-pot SAMPLE OUT 3. Is the MFC reading correctly? MV 3 Cleaning MV 7 Injection MFC BYPASS MV 9 Manual STREAM 1 OXYGEN MV 4 Sample In Oxygen module P 1 Sample Pump 2. Is the O 2 pressure correct? STREAM 2 MANUAL MV 6 Acid ACID Mixer P 3 Acid Pump P 2 4. Disconnect Ozone outlet tube. Seal ozone outlet. Test. MV 11 Stream 2 5. Disconnect cooler outlet tube. Seal cooler tube. Seal sample out valve. P 4 Base Pump Test. Reactor MV 5 Sample Out Examples of some potential leak points in the B 7000 i. BASE

Flow Test • Purpose: - To detect a blockage or partial blockage in a gas flow path Bio. Tector • Frequency of activation: - Once per day, and when the Bio. Tector 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 Bio. Tectors 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 O 2 Flow fault setting) within the 30 second flow test time, a flow warning is logged - If the gas flow drops below 30 LPH, a flow fault is logged and the Bio. Tector stops Note: In addition to the Flow Test detailed above which operates once per day and each time the Bio. Tector 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 Bio. Tector stops

Typical Flow Test Menu F L O W T E S T 0 9 : 1 7 : 2 8 1 2 - 0 9 - 0 2 1 < * E X H A U S T T E S T 2 E X H A U S T F L O W 3 S A M P L E O U T T E S T 4 S A M P L E O U T F L O W T I M E 3 0 s M F C S E T P O I N T 6 0. 0 l / h M F C F L O W 5 8. 3 l / h S T A T U S T E S T I N G P R E S S E S C T O A B O R T T H E T E S T Two modes available for each valve: • Exhaust (or Sample Out) Test: Simulate the flow test using the same time the Bio. Tector allows (30 s) • Exhaust (or Sample Out) Flow: Simulate the flow test with long time limit, useful for detecting a blockage

Flow Test: Exhaust Valve blocked? Ozone Generator Air Pressure correct? MV 1 Exhaust Cooler CO 2 Analyser EXHAUST Ozone destructor filter blocked? Oз Destructor Air AIR Line blocked outside Bio. Tector? Oxidized Fluid Catch-pot SAMPLE OUT MFC reading correctly? MV 3 Cleaning MV 7 Injection MFC BYPASS MV 9 Manual STREAM 1 MV 4 Sample In OXYGEN MV 11 Stream 2 STREAM 2 P 1 Sample Pump MANUAL O 2 Pressure correct? MV 6 Acid Oxygen module ACID Mixer P 3 Acid Pump P 2 Oxygen inlet to reactor blocked? BASE P 4 Base Pump Reactor MV 5 Sample Out Above are some examples of some potential blockage points in the Bio. Tector 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

Flow Test: Exhaust 5. Disconnect tube after ozone destructor. Test. 6. Disconnect tube outside Bio. Tector. Test. Ozone Generator 1. Is the Air Pressure correct? MV 1 Exhaust 4. Disconnect tube before ozone destructor. Test. CO 2 Analyser Cooler AIR EXHAUST Oз Destructor 7. Disconnect tube over cooler. Test. Air Oxidized Fluid Catch-pot SAMPLE OUT 3. Is the MFC reading correctly? Test only when system depressurized. MV 3 Cleaning MV 7 Injection OXYGEN MFC BYPASS MV 9 Manual STREAM 1 MV 4 Sample In 8. Disconnect tube at TEE, but only when system de-pressurized. P 1 Sample Pump Test. 2. Is the O 2 Pressure correct? MV 11 Stream 2 STREAM 2 MANUAL MV 6 Acid Oxygen module ACID Mixer P 3 Acid Pump P 2 BASE P 4 Base Pump Reactor MV 5 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.

Flow Test: Sample Out Ozone Generator Air Pressure correct? MV 1 Exhaust EXHAUST Oз Destructor CO 2 Analyser Cooler AIR Air Valve blocked? Line blocked outside Bio. Tector? Oxidized Fluid Catch-pot SAMPLE OUT MFC reading correctly? MV 3 Cleaning MV 7 Injection MFC BYPASS MV 9 Manual STREAM 1 MV 4 Sample In OXYGEN MV 11 Stream 2 STREAM 2 P 1 Sample Pump MANUAL O 2 Pressure correct? MV 6 Acid Oxygen module ACID Mixer P 3 Acid Pump P 2 Valve blocked? BASE P 4 Base Pump Reactor MV 5 Sample Out Above are some examples of some potential blockage points in the Bio. Tector 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

Flow Test: Sample Out Ozone Generator 1. Is the Air Pressure correct? MV 1 Exhaust EXHAUST Oз Destructor CO 2 Analyser Cooler AIR Air Oxidized Fluid Catch-pot SAMPLE OUT 3. Is the MFC reading correctly? MV 3 Cleaning MV 7 Injection OXYGEN MFC BYPASS MV 9 Manual STREAM 1 MV 4 Sample In 4. Disconnect Ozone outlet tube, but only when system de-pressurized. P 1 Sample Pump Test. 2. Is the O 2 Pressure correct? 6. Disconnect sample out MV 11 Stream 2 tube. Test. STREAM 2 MANUAL MV 6 Acid Oxygen module ACID Mixer P 3 Acid Pump P 2 5. Disconnect Tube after the valve. Test. BASE P 4 Base Pump Reactor MV 5 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.

Ozone Test • Purpose: - To check the level of ozone generated by the Bio. Tectors ozone generator The ozone test uses the procedure described in information sheet “T 021. Procedure to check the ozone level in Bio. Tector 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 T 021 and the installation confirmed by the user, the Bio. Tector activates the ozone generator – The Bio. Tector 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 T 021. 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.

Typical Ozone Generator Test Menu When the ozone generator test has been installed in accordance with T 021, 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 18 s (or programmed level), the status of the ozone test is Pass If the o-ring breaks in a time between 18 and 60 s, the status of the ozone test is Low Ozone If the o-ring does not break within 60 s, the status of the ozone test is Fail

Ozone Generator Test Warning: Only work on ozone generator if mains power is isolated Ozone Generator MFC Oxygen purity >93% oxygen, and free of water and oil? MV 7 Injection 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.

Sample Pump Test • Purpose: - 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 Bio. Tector 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

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

Sample Pump Test: Forward The sample should be pumped out the drain and on for 1 meter.

Sample Pump Test: Reverse Sample and oxidized fluid should be completely pumped back to sample point.

p. H Test • Purpose: - To check the p. H in the reactor at different stages in the reaction The user must understand the procedure for testing the p. H in the Bio. Tector Use eye protection and gloves Have all the relevant parts for this test ready (primarily beaker and p. H paper) before carrying out the test • Operation: - The p. H 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 p. H to be checked - The process is repeated for the Base reagent and the TOC acid reagent

Typical p. H 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 p. H • Only a very small sample should be removed from the reactor, so as not to effect the p. H for the next test • It is important that the previous reaction finished normally to eliminate the possibility of any p. H influence from the previous reaction

p. H Test: Example TIC p. H Test Ozone Generator MV 1 Exhaust EXHAUST Oз Destructor CO 2 Analyser Cooler AIR Air Oxidized Fluid Catch-pot SAMPLE OUT MV 3 Cleaning MV 7 Injection MFC BYPASS MV 9 Manual MV 11 Stream 2 STREAM 1 MV 4 Sample In OXYGEN P 1 Sample Pump MV 6 Acid Oxygen module Mixer P 2 With the reactor mixer stopped, the liquid accumulates at the bottom of the reactor. STREAM 2 MANUAL ACID P 3 Acid Pump BASE MV 5 Sample Out Reactor er p. H pap P 4 Base Pump 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. Above is an example of testing the p. H 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 p. H. Only a very small sample should be removed from the reactor, so as not to effect the p. H for the next test.

p. H Test: Commonly Found Issues Ozone Generator MV 1 Exhaust EXHAUST Oз Destructor CO 2 Analyser Cooler AIR Air Oxidized Fluid Catch-pot SAMPLE OUT MV 3 Cleaning MV 7 Injection MFC BYPASS MV 9 Manual MV 11 Stream 2 STREAM 1 OXYGEN MV 4 Sample In Are the programmed settings for sample, acid and base correct? MANUAL Is the p. H in the sample very high ~>11 p. H or very low ~<3 p. H? MV 6 Acid Oxygen module STREAM 2 P 1 Sample Pump ACID Mixer Acid, Base pump: pumped volume correct? P 2 P 3 Acid Pump BASE MV 5 Sample Out Reactor mixer mixing liquid? Reactor Here are shown some examples of where p. H issues could occur P 4 Base Pump Acid, Base reagents: Is the normality correct?

Sample Valve Test • Purpose 1: – 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. • Reason: – 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 “M 046 Sample Valve Adjustment and Sample Tube Positioning Guidelines”.

Typical Sample Valve Test Menu S A M P L E V A L V E T E S T 0 9 : 1 7 : 2 8 1 2 - 0 9 - 0 2 1 < * T E S T F I R S T F A I L U R E 2 S E N 1 S E N 2 S E N 3 3 A D J U S T S A M P L E V A L V E 0 , 0 L O O P C O U N T 1 S E N 1 S E N 2 S E N 3 C U R R E N T L Y T E S T I N G 0 , 0 F I R S T F A I L U R E P O I N T 0 , 0 P R E S S E S C T O A B O R T T H E T E S T • The final “Adjust Sample Valve” settings should be 6 points or more below the “First Failure” point.