Dangote Petroleum Refinery &

Petrochemicals FZE

Standard Maintenance Procedure for HACH 5500sc Silica Analyzer

Standard Maintenance Procedure for HACH 5500sc Silica Analyzer

Maintenance Department – Instrumentation

A soft copy of this document, maintained on the Dangote Petroleum Refinery &
Petrochemicals FZE Intranet, is the controlled version.
When printed, this document is considered uncontrolled.

Analyzer Tag Numbers

*Refer Plant specific Analyzer tag nos

Signature:
Satheeshkumar.P.S
Prepared By: Document# DPRP-OM-SMP-ANA-XXXX
Analyzer Engineer

Pinakin Macwan
Reviewed By: Revision# 00
Lead – Analyzer System

Kandasamy Ponnusamy
Approved By: Date:
HOD Instrumentation

* This Signatures apply to entire Document

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Standard Maintenance Procedure for HACH 5500sc Silica Analyzer

TABLE OF CONTENTS

1 PURPOSE:.......................................................................................................................

2 Environment, Health & Safety Precautions:..............................................................

3 Analyser Working Principle:........................................................................................

4 Calibration/Validation:..................................................................................................

5 Routine Checks.............................................................................................................

6 Forms / Records:..........................................................................................................

7 References:....................................................................................................................

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Standard Maintenance Procedure for HACH 5500sc Silica Analyzer

1. Purpose:

The purpose of this procedure is to define standard maintenance process and guide line to carry
out general maintenance and Calibration/Validation of HACH 5500sc Silica Analyzer.
Refer Operation and maintenance manual for specific/detailed maintenance activities
Definition:
DPRP: Dangote Petroleum Refinery & Petrochemicals
DORC: Dangote Oil Refining Company
OM: Operation & Maintenance
INST: Instrumentation
ANA: Analyzer
AMADAS: Analyzer Management and Data Acquisition System
O2: Oxygen
Comb: Combustible
HC: Hydro Carbon
CAL: Calibration
VAL: Validation
GC: Gas Chromatograph
SCS: Sample Conditioning System
SHS: Sample Handling System
PreSCS: Primary Sample Conditioning System
PRV: Pressure relief Valve
AOV: Air Operating Valve
SOV: Solenoid Operating Valve
TSV: Temperature Shut-Off Valve
MSDS: Material Safety Data Sheet
PM: Preventive Maintenance
CM: Corrective Maintenance
MCR: Main Room Operator
DCS: Distributed Control System
ESD: Emergency Shutdown System.
FGS: Fire & Gas System
MCR: Main Control Room
SRR: Satellite Rack Room
SMP: Standard Maintenance Procedure
SOP: Standard Operating Procedure
CMMS: Computerized Maintenance Management System
PTW: Permit to Work System
TRA: Task Risk Assessment

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Standard Maintenance Procedure for HACH 5500sc Silica Analyzer

2. Environment, Health & Safety Precautions:

 Company HSE regulations & PTW system shall be followed for any work carried out on
HACH 5500sc Silica Analyzer along with a specific Risk Assessment as applicable.
 Verify all the PPE mentioned in the PTW are worn by the person carrying out the task.

3. Analyzer Working Principle:

Silica Measurement:
 Silica in the sample reacts with molybdate ions under acidic conditions to form
silicomolybdic acid complexes. Addition of citric acid destroys the phosphate complexes. Amino
Acid Reagent is then added to reduce the yellow silicomolybdic acid to an intense blue color,
which is proportional to the silica concentration. Test results are measured at 815 nm.

Stream Selector (SAMYAK Model-SS301):

 This STREAM SELECTOR UNIT is upgraded version of Samyak make stream selector.
The unit has 20 characters x 4 lines LCD. This makes it more users’ friendly. It is based on a
popular 8-bit Microcontroller. The system is designed to control stream selection of up to eight-
stream system using its Relay outputs and sync Input or Timer. It also generates Sample and
Hold analog outputs for each channel
 The system is based on an 8-bit micro-controller. It is to be used for selecting one of the
EIGHT streams in accordance with SYNC. Pulse from Analyser if trigger mode is Pulse. Stream
selection will be according to pre-programmed timings if trigger mode selected is TIME.

4. Calibration/Validation:
 After receiving PTW Consult with field operator and confirm the Analyzer tag number is
correct at the location before proceeding and make sure control loop in manual mode. Also
ensure that if Analyzer is in interlock, then make sure that it is removed from interlock till
maintenance work is done and Analyzer is taken back in line.
 Refer HACH 5500sc Manual to Perform Calibration/Validation of the Analyzer.
 Refer Samyak Stream Selector SS301 Manual to Perform Calibration of the Analyzer.
 Check and confirm the validity of calibration solution & Reagents.
 Refer Analyzer P&ID to check the Set point of the Flow, Pressure for the Analyzer

Note:
1. Validate the Analyzer every 30 Days,
2. Replace the reagents every 60 Days (Replace the reagent(s) or standard(s) before
the level in the analyzer bottle(s) is less than 10%.),
3. Replace the standards & Calibrate the analyzer every 90 days as a standard
practice. Follow plant specific schedule in case if required
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Standard Maintenance Procedure for HACH 5500sc Silica Analyzer

4. Clean or replace the sample (y-strainer) filter, fan filter, reagent air filter, stir bar,
sample cell every 365 Days.
5. Routine Checks:

 Follow plant specific routine checks.

 Check and confirm Flow settings, pressure and temperature at various points as per
Analyzer flow schematics
 Check calibration standard solution, reagent validity as applicable
 Check if any abnormal alarms appearing on Analyzer shelter / cabinet or Analyzer as
applicable

6. Forms / Records:

 Analyzer Calibration Sheet: DPRP-OM-CAL-ANA-XXXX

 Analyzer Preventive Maintenance Sheet: DPRP-OM-PM-ANA-XXXX
 Analyzer Standard Operating Procedure: DPRP-OM-SOP-ANA-XXXX

7. References:

 P & IDs
 Analyzer Data sheet & Flow schematics
 OEM – Operating and Maintenance Manual
 MSDS – As applicable

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Standard Maintenance Procedure for HACH 5500sc Silica Analyzer

Preventive Maintenance Checklist for HACH 5500sc Silica Analyzer

Tag No: Check sheet No: DPRP-OM-PM-ANA-XXXX
Permit No: Date:
Description Action Taken Remarks

Inform the Control Room operator before commencing the

work.
Ensure Control system which includes the equipment has
been properly overridden and got OK from Control Room
operator – If Applicable
Check condition of Sample tubes and leak check the
connectors wherever applicable
Check & Clear any Alarms in the HMI & report to supervisor &
Panel Operator immediately
Check the Condition of the Stream Selector, Record the
Stream Cycle.
Clean the exterior of the instrument with a moist cloth and a
mild soap solution
Sample line and valve cleanup, Clean the sample cell
Check the conditions & record the measured values of the following:
Description As Found After
Correction
Analyzer PV
DM Water Supply
Analyzer Data
Cell Temperature
Reagent Temperature
Ambient Temperature
Sample Temperature
Air Pressure
LED Duty Cycle ((typically 7,200 to 40,000 counts)
Heater Duty Cycle
Sample Flow
Sample Pressure 1
Sample Pressure 2
Reagent 1 Level
Reagent 2 Level
Reagent 3 Level
Standard Solution Level
Fan Speed

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Standard Maintenance Procedure for HACH 5500sc Silica Analyzer

Leak Counts
Measurement Data
Last Measurement Channel
Last Measurement Time
Last Absorbance Reading
Last Concentration Reading
Next Measurement Time
DARK (Number of A/D Counts when LED Turned OFF)
REF (Reference A/D Count used to compensate for
natural color & Turbidity)
Sample (Determine the Conc. of the Sample)
Dark Standard Deviation
Reference Standard Deviation
Sample Standard Deviation
Sample Volume
Reagent 1
Reagent 2
Reagent 3
Check the Canopy or Cabinet Lights, Air Conditioner were in
Good & Working Condition
Perform Housekeeping.

Performed By Reviewed By (Supervisor) Approved By (Engineer)

(Technician)
Name: Name: Name:

Date: Date: Date:

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