NGHI SON REFINERY AND PETROCHEMICAL LLC

Amendment Table

Rev. Prepared Reviewed Approved

Date Description
No. by by by
NS. Binh/
00 05.02.16 Initial release HC. Nam T. Sugimura
T. Kimura

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AMENDMENT REPORT FORM

No. Item Original Revised Reason

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Contents

1. PURPOSE ..................................................................................................................... 5
2. SCOPE .......................................................................................................................... 5
3. RESPONSIBILITY ......................................................................................................... 5
4. DEFINITION & ABBREVIATION .................................................................................... 5
5. REFERENCE ................................................................................................................. 5
6. PROCEDURE ................................................................................................................ 6
6.1 Overview of TELEDYNE 6700 TOC/COD Analyzer............................................... 6
6.2 Prepare the work .................................................................................................... 7
6.2.1 Confirmation of Work Order and Safety requirements ........................................... 7
6.2.2 Special Personal Protective Equipment ................................................................. 7
6.2.3 Environmental Precautions .................................................................................... 8
6.2.4 Equipment and Tools ............................................................................................. 8
6.2.5 MRO for maintenance ........................................................................................... 8
6.3 Execute the work .................................................................................................... 9
6.3.1 Visual check of TOC/COD Analyzer ...................................................................... 9
6.3.2 Maintenance of Total Organic Carbon Analyzer................................................... 11
6.3.3 Function checking (N/A) ...................................................................................... 13
6.3.4 Return equipment to service ................................................................................ 13
6.4 Work Order closure .............................................................................................. 14
7. APPENDIX ................................................................................................................... 15
7.1 Appendix for Total Organic Carbon Analyzer Check sheet (1)......................... 15
7.2 Appendix for Total Organic Carbon Analyzer Check sheet (2)......................... 16
7.3 Appendix for Total Organic Carbon Analyzer Check sheet (3)......................... 17
7.4 Appendix for Total Organic Carbon Analyzer Check sheet (4)......................... 18
7.5 Appendix for Total Organic Carbon Analyzer Check sheet (5)......................... 19

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1. PURPOSE
This procedure is to provide the maintenance instruction for preventive maintenance
of Total Organic Carbon/ Chemical Oxygen Demand (TOC/COD) Analyzers in Nghi
Son Refinery & Petrochemical LLC. (NSRP), hereafter called Refinery or NSRP.
2. SCOPE
This procedure is applied for preventive maintenance of TOC/COD Analyzers in
Refinery. This document includes maintenance instruction and also provides the
safety requirements for NSRP/DMC personnel.
This procedure extracts important prescriptions from Vendor or Manufacturers
maintenance manual. Refer to Vendors maintenance manual for further information.
3. RESPONSIBILITY
This procedure is approved by Division Manager (DM) of Maintenance division.
Section Manager (SM) of Reliability Engineering section is responsible for issuing and
distributing the procedure. The procedure will be reviewed periodically, revised and
updated as needed. The SM of Reliability Engineering section reserves the right to
make any amendment and modification to this procedure subject to requirements of
proper management.

4. DEFINITION & ABBREVIATION

CMMS Computerized Maintenance Management System
DMC Daily Maintenance Contractor
HSE Health, Safety and Environment
LOTO Lock-Out Tag-Out
MRO Maintain, Repair and Operate material
MSDS Material Safety Data Sheets
NSRP Nghi Son Refinery & Petrochemical LLC.
PM Preventive Maintenance
PTW Permit To Work
WO Work Order
SCS Sample Conditioning System
SPCS Sample Pre-Conditioning System
5. REFERENCE
Document Number Title
- ISRS V8.1 Book of Knowledge

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- ISRS V8 Workbook
Preventive Maintenance Workflow for Production
MD-03-MT-WF-001
Facilities
Breakdown Maintenance Workflow for Production
MD-03-MT-WF-005
Facilities
(Later) PTW Procedure
M6700C-C 3/06/12 Teledyne Operating Instructions for Model 6700C
6. PROCEDURE
6.1 Overview of TELEDYNE 6700 TOC/COD Analyzer

A Series 6700 TOC Analyzer is comprised of 5 subsystems:

1- Sample Conditioning
2- Total Inorganic Carbon (TIC) removal OR Total Inorganic Carbon analysis/TOC
True method
3- Oxidation
4- NDIR CO2 gas detection
5- Electronic signal processing, display, and control

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6.2 Prepare the work

6.2.1 Confirmation of Work Order and Safety requirements
Any preventive maintenance activity shall be performed in accordance with approved
preventive maintenance schedule. Through CMMS, the WO will be generated and
approved before execution. The maintenance team leader and his team members
who are assigned the work shall carefully check the requirements on WO and
carry-out following activities:
- Check the Equipment ID/Tag name as per Work Order.
- Check the location, elevation, and access way possibility to the TOC/COD Analyzer.
- Check the datasheet and make sure to understand the process condition and type of
TOC/COD Analyzer.
- Identify any escape route in case of emergency.
- Confirm and obtain necessary advices from Operation.
- If the maintenance work is high risk, discuss the contingency and mitigation plans.
Also, request HSE to approve.
- Obtain approval of hot work permit where the work could create a sparking (fire)
hazard including use of electric testing equipment (with or without battery cells).
- Obtain all Permits to Work required within the scope of work as per PTW Procedure
(Later).
- Conduct a Safety Toolbox Meeting with dedicated craftsmen and workers to discuss
the following:
Work purpose, scope, expected duration, risk assessment, MSDS, Vendor
documents, drawings, etc.
Do not operate or do any maintenance activity even opening equipment cover
of other equipment that are not in PTWs scope.
Uncontrolled PTWs scope or incorrect isolation will become hazardous e.g.:
equipment damage, human injury, explosion, or Refinery shut down.
Required isolation, LOTO certificates to be done shall be confirmed.
Consider any possible interference in the work area, and any possible action to
be taken.
6.2.2 Special Personal Protective Equipment
The personnel who involves into the activity are required to wear the standard
personal protective equipment (PPE). Additional PPE must be worn for this procedure
due to the nature of the work or the location.
- Personal protective hydrogen sulfide (H2S) detector must be worn in designated

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areas.
- Suitable gloves must be worn when handling hazardous materials or contacting a
cold or hot surface.
- Double ear protection (Ear plug & Ear muff) must be attached before entering the
area with noise level above 85 dB.
- Be aware of potential hazards when working around oil and gas lines.
- Safety eyes glasses must be worn when handling chemical products.
6.2.3 Environmental Precautions
Maintenance is conducted in accordance with governmental requirements for
protection of the environment.
- Make sure good housekeeping is carried out during and after each work.
- Do not drain or vent any liquid or gas to an open space, on the ground, or into the
sea. Use only the approved method to drain or vent the systems.
- Gather all waste maintenance materials produced during work. After work, move and
store them at the reserved place.
6.2.4 Equipment and Tools
Except conventional equipment and tools, the following equipment and tools may be
necessary for maintenance work:
- HART Communicator with valid calibration date
- Digital Multi-Meter with valid calibration date
- Bottle of Snoop leak detector for liquid
- Handheld leak detector suitable for Hydrogen application
- Portable Flowmeter
6.2.5 MRO for maintenance
Depending on the requirements on WO, the following MRO may be required:
- HOLD
In addition to the above, conventional or consumable material is required, such as rag,
brush.
NOTE:
HOLD

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6.3 Execute the work

6.3.1 Visual check of TOC/COD Analyzer

Sample Probe at field

Work
Description Remarks
step
Inform the Control Room operator before
commencing the work. The radio shall be kept
to make sure communication with operator in
1
the Control Room in case the piece of
equipment needs to be returned to service for
any reason.
If there is any leak, inform
Control Room operator
that the action LO/TO
shall be followed as per
Leak check with Snoop leak detector at Procedure LO/TO (Later).
2 sample probe isolation valve(s) outlet to This Procedure shall be
sample inlet of Sample Conditioning System. ABORTED at this point.

In case of NO LEAK,
move to Step 3.
Check condition of Sample lines
and In order to prevent any
3
components: contamination of the
sample, lines and
1-Tag nameplate of Sample Isolation Valve(s) components must be free
of corrosion, free of
2-Sample Isolation Valve(s) body grease, clean.

3-Sample lines

4-Supports, Safety Ground Integrity of the lines and

components must be
5-Others (to be specified) maintained.

4 Fill in the Checks sheet 1. Appendix 7.1.1

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Sample Conditioning System (SCS) outside Shelter

Work
Description Remarks
step
Check condition of SCS and components,
and Leak check with Snoop leak detector
1
each component of SCS, at inlet, outlet &
vent port (if applicable): In order to prevent any
contamination of the
1-Tag nameplate of Enclosure sample, SCS and
components must be free
2-Pressure Gauge of corrosion, free of
grease, clean. Integrity of
3-Pressure Regulator the connecting lines and
components must be
4-Safety Relief valve maintained.
Lines and components
5- Restrictor Flowmeters must be pressure-tight to
prevent diffusion of
5-Ball valve moisture and/or
atmospheric gases, and
6-Strainer contamination of the
sample.
7-Needle valve .

8-Lab Tab

9-Safety Ground

2 Fill in the Checks sheet 2. Appendix 7.1.2

Work
Description Remarks
step
Record the measured values of the following Flow, Pressure and
3 Temperature (if
instruments inside SCS: measured) are the three
process variables
1-Pressure Gauge required for the correct
operation of TOC/COD
2-Pressure Regulator Gauge Analyzer.
They must be recorded
3-Restrictor Flowmeter routinely.

4 Fill in the Checks sheet 3. Appendix 7.1.3

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6.3.2 Maintenance of TOC/COD Analyzer

Work
Description Remarks
step
Check status conditions of Analyzer
components and Leak check with Snoop leak
1 detector each component and lines at the entry
of TOC/COD Analyzer, at inlet, outlet & vent
port (if applicable):
1-Sample line connections at Sample IN of
TOC/COD Analyzer
2-Sample line connections at Sample OUT of
TOC/COD Analyzer
3-IA line connections to TOC/COD Analyzer
Purge Enclosure

4-IA Pressure Regulator to Purge Enclosure

5-IA Safety Relief valve on Purge Enclosure
line
6-IA Pressure Regulator to Carrier Gas Filters

7- IA Safety Relief valve to Carrier Gas Filters

8-Restrictor Flowmeter to Carrier Gas Filters

9-ZERO Solution to Analyzer

10-SPAN Solution to Analyzer

11-ACID Reagent solution to Analyzer

12-DI H2O solution to Analyzer

13-SODIUM Persulfate solution to Analyzer

14-Vent line connections to ATM Vent

15-Drain lines to WO Drain

16-Safety Ground
2 Fill in the Checks sheet 4. Appendix 7.1.4

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Work Description Notes

Step
Record the measured values of the following
3
instruments:

1-Inlet Sample Pressure

2-IA Pressure Regulator Gauge to Purge Unit

3-IA Pressure Regulator Gauge to Carrier Gas

Filters

4-Inlet Sample Flow

4 Fill in the Checks sheet 5. Appendix 7.1.5

Work
Description Remarks
step
At the Front Panel display and keypad, take
5
note of the following:

1-TOC reading (Note I)

2-COD reading (Note II)

3-List of alarms (Note III)

6 Fill in the Checks sheet 5. Appendix 7.1.5

Note I: Maintenance of TOC

Aside from normal cleaning and checking for leaks at the connections, the Model 6700C
should not require any maintenance beyond recalibration.
Prior to performing any detailed troubleshooting procedures, it is suggested to first perform
computer-aided testing of the analyzer using the built-in test routine as described here after.

From the screen, Select [Test]. The following menu appears:

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Select [System Diagnostics]. The following menu appears:

From this screen the operator may perform individual testing of components related to
functionality and settings.
Refer to Manual 6700C at Section 5.2 Troubleshooting Guide page 41.
(End of Note I)

Note II: List of Alarms & Error Messages

For more details, please refer to:
- Instruction Manual .HOLD. Section HOLD Error Messages Page HOLD
(End of Note II)

6.3.3 Function checking (N/A)

NOT APPLICABLE

6.3.4 Return equipment to service

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Work
Description Remarks
step
Remove all temporary equipment and
maintenance equipment
1 NOTE:
Make sure the equipment is ready to be
returned to service.
2 Keep the maintenance area tidy
Close all PTW and confirm with Operation the
work is completed.
3 NOTE:
Make sure all isolation, LOTO (if any) are
released and confirmed.
After Step 3, Operation will be responsible to
carry-out commissioning.
NOTE: (for special case)
4 If required, parameter or status of
equipment shall be recorded in check
sheet during commissioning.
The WO can be completed only after
commissioning is passed
6.4 Work Order closure
Refer document MD-04-MT-MS-PD-006_Maintenance Closure Procedure for further
requirements.
Work
Description Remarks
step
1 Sign-off all check sheets or record sheets

Return unused spare parts and reusable parts:

Gather unused parts and return them to
2 Warehouse after approval.
Gather all reusable parts that can be
refurbished
Record and summary of the maintenance work:
Actual used MRO,
3 Actual used Equipment/Tool
Actual man hour
Send the endorsed WO for CMMS recording
Record in CMMS. To be done by NSRP
4
Complete WO on CMMS (Refer the note in (HOLD)

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Step 4 in paragraph 6.3.4)

To be done by NSRP
5 Close WO on CMMS
(HOLD)
7. APPENDIX

7.1 Appendix for TOC/COD Analyzer Check sheet (1)

CHECK SHEET: Inspection work Modification work

MAINTENANCE OF TOC/COD ANALYZER Maintenance work Calibration work

Overhaul work Other

MAINTENANCE DIVISION

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Equipment Tag No.: Check sheet No.:

WR No.: Description: Discipline: ANALYZER

WO No.: Description: Date:

Time In: h Time Out: h Down Time: h

SAMPLE LINE & VALVE

Check condition of Sample lines and AS AS

ACTION
components, and leak check FOUND LEFT
1-Tag nameplate of Sample Isolation OK OK
Valve NOK
2-Sample Isolation Valve body OK OK
NOK
3-Sample lines and insulations OK OK
NOK
4-Supports, Safety Ground OK OK
NOK
5-Others (To be specified) OK OK
NOK

Remarks:

Contractor NSRP Supervisor NSRP Operation Third party (if any)

Signature
Name
Date
7.2 Appendix for TOC/COD Analyzer Check sheet (2)
CHECK SHEET: Inspection work Modification work

MAINTENANCE OF TOC/COD ANALYZER Maintenance work Calibration work

Overhaul work Other

MAINTENANCE DIVISION
Equipment Tag No.: Check sheet No.:

WR No.: Description: Discipline: ANALYZER

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WO No.: Description: Date:

Time In: h Time Out: h Down Time: h

SAMPLE CONDITIONING SYSTEM

Check condition of SCS and AS ACTION AS

components, and leak check: FOUND LEFT
1-Tag nameplate of SCS Enclosure OK OK
NOK
2-Pressure Gauge OK OK
NOK
3-Pressure Regulator OK OK
NOK
4- Restrictor Flowmeter OK OK
NOK
5-Ball valve OK OK
NOK
6-Strainer OK OK
NOK
7-Needle valve OK OK
NOK
8-Lab Tap OK OK
NOK
9-Safety Ground OK OK
NOK

Contractor NSRP Supervisor NSRP Operation Third party (if any)

Signature
Name
Date
7.3 Appendix for TOC/COD Check sheet (3)
CHECK SHEET: Inspection work Modification work

MAINTENANCE OF TOC/COD ANALYZER Maintenance work Calibration work

Overhaul work Other

MAINTENANCE DIVISION
Equipment Tag No.: Check sheet No.:

WR No.: Description: Discipline: ANALYZER

WO No.: Description: Date:

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Time In: h Time Out: h Down Time: h

SAMPLE CONDITIONING SYSTEM AS AS NOMINAL

Measurements FOUND LEFT
1 Sample Inlet Gauge Pressure (kPa-g),
Tag name:
2 Pressure Regulator Gauge (kPa-g),
Tag name:
3 Restrictor Flowmeter at Filter (l/min),
Tag name:

Remarks:

Contractor NSRP Supervisor NSRP Operation Third party (if any)

Signature
Name
Date
7.4 Appendix for TOC/COD Analyzer Check sheet (4)
CHECK SHEET: Inspection work Modification work

MAINTENANCE OF TOC/COD ANALYZER Maintenance work Calibration work

Overhaul work Other

MAINTENANCE DIVISION
Equipment Tag No.: Check sheet No.:

WR No.: Description: Discipline: ANALYZER

WO No.: Description: Date:

Time In: h Time Out: h Down Time: h

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LAR TOC/COD ANALYZER SYSTEM

Check condition of TOC/COD Analyzer enclosure

AS AS
& connecting lines, Leak check IN/OUT/VENT of ACTION
FOUND LEFT
components:
1-Tag nameplate of TOC/COD Analyzer OK OK
NOK
2-Sample lines connections at Sample IN of TOC OK OK
Analyzer NOK
3-Sample lines connections at Sample OUT of OK OK
TOC Analyzer NOK
4-IA line connections to TOC Analyzer Purge Unit OK OK
NOK
5-IA Pressure Regulator to Analyzer Purge Unit OK OK
NOK
6-IA Pressure Regulator to Carrier Gas Filters OK OK
NOK
7-CAL Solution lines to TOC Analyzer OK OK
NOK
8-Reagent Solution lines to TOC Analyzer OK OK
NOK
9-Acid Solution lines to TOC Analyzer OK OK
NOK
10-Vent lines connections to ATM Vent OK OK
NOK
11-Safety Ground OK OK
NOK

Remarks:

Contractor NSRP Supervisor NSRP Operation Third party (if any)

Signature
Name
Date
7.5 Appendix for TOC/COD Analyzer Check sheet (5)
CHECK SHEET: Inspection work Modification work

MAINTENANCE OF TOC/COD ANALYZER Maintenance work Calibration work

Overhaul work Other

MAINTENANCE DIVISION
Equipment Tag No.: Check sheet No.:

WR No.: Description: Discipline: ANALYZER

WO No.: Description: Date:

Time In: h Time Out: h Down Time: h

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LAR TOC/COD ANALYZER SYSTEM AS AS NOMINAL

Measurements FOUND LEFT
1 Sample IN Gauge Pressure (kPa-g),
Tag name:
2 IA Pressure Regulator Gauge to Purge Unit (kPa-g)
Tag name:
3 IA Pressure Regulator Gauge to Carrier Gas Filters (kPa-g)
Tag name:
4 Sample IN of TOC Analyzer (L/min)
Tag name:
5 TOC value (mg/l)
Tag name:
6 COD value (mg/l)
Tag name:
7 List of Alarms: N/A N/A N/A

Remarks:

Contractor NSRP Supervisor NSRP Operation Third party (if any)

Signature
Name
Date

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