10th ISESCO-COMSATS’ National Workshop

on

‘Repair and Maintenance of Scientific, Engineering Equipment in Universities, Research Institutions and

Small Scale Industries’

Almaty, Kazakhstan

October 02-06, 2017

Commission on Science and Technology for Sustainable Development in the South

(COMSATS)

CONTENTS

1. Introduction .................................................................................................................... 1 2. Objectives ....................................................................................................................... 1 3. Outcomes of the workshop .............................................................................................. 2 4. Conclusion ...................................................................................................................... 2 5. Recommendations........................................................................................................... 2 6. Future action plan ........................................................................................................... 3 7. Program schedule (Annexure-A) .................................................................................... 4 8. List of instruments (Annexure-B).................................................................................... 7 9. List of participants (Annexure-C).................................................................................... 9 10. Program brochure (Annexure-D)..................................................................................... 9 11. Picture gallery (Annexure-E) ........................................................................................ 10

12. LECTURE SLIDES

1. General Repair & Maintenance Techniques ................................................................................. 13 2. General Tools for Repair & Maintenance ..................................................................................... 21 3. Spectrophotomer ........................................................................................................................... 26 4. Flame Photomete .......................................................................................................................... 31 5. Atomic Absorption ...................................................................................................................... 39 6. XRF Systems ............................................................................................................................... 44 7. Gas Chromatograph ..................................................................................................................... 51 8. HPLC Systems ............................................................................................................................. 56 9. Thermal Equipment (Oven, Furnace, Inqubator) ......................................................................... 65 10. Melting Point Apparatus .............................................................................................................. 74 11. TGA, DSC Systems ...................................................................................................................... 76 12. Bomb Calorimeter ....................................................................................................................... 85 13. High Vaccum Technology .......................................................................................................... 89 14. CHNS Analyzer ........................................................................................................................... 97 15. Viscometer ................................................................................................................................ 102 16. Analytical Balances ................................................................................................................... 105 17. pH meter ................................................................................................................................... 108 18. Refractometer ............................................................................................................................ 111

1

INTRODUCTION Scientific instruments play a vital role in research institutes, academia and industry. They are widely used in R&D, quality control, testing and analysis, which leads to socioeconomic development of a country. These instruments are very expensive and are mostly imported against huge foreign exchange. Besides the challenge of procurement of such instruments, the repair and maintenance is another a great challenge. The operational trainings are usually arranged with the procurement of instruments, however, the repair and maintenance related trainings are mostly avoided either due to the unavailability of such trainings or the huge charges involved. The unavailability of such training programs and the inability of repair and maintenance thus lead to abandonment of large number of faulty instruments. In under developing countries, the situation is more crucial where they have limited resources for the execution of R&D programs especially in the government sector. To resolve the issue, they particularly look for financial or free technical support to relive their expensive fault instruments. In realization of the importance of the issue and to enable the Islamic countries to achieve technological self-reliance in repair and maintenance of scientific equipment and to reduce the technological dependence on the foreign experts, the Commission on Science and Technology for Sustainable Development in the South (COMSATS) and Islamic Educational, Scientific and Cultural Organization (ISESCO), initiated a series of national workshops in 2004. After the successful organization of first national workshop in Sudan, both organizations have successfully organized similar events in Nigeria (2016), Oman (2015), Iran (2014), Ghana (2013 & 2015),Sudan (2004 & 2013),Tunisia (2012), Egypt (2011), Senegal (2010) and Syria (2005). These workshops have benefited over 330 scientists, researchers, engineers and technicians by building their expertise and capacity to indigenously repair and maintain scientific instruments used in the labs of R&D institutions as well as small-scale industries in their respective countries. Under COMSATS-ISESCO cooperation programme for 2017, the national workshop entitled “Repair and Maintenance of Scientific Engineering Equipment in Universities, Research Institutions and Small Scale Industries” held in Kazakhstan, from October 02-06, 2017 in collaboration with Al Farabi Kazakh National University (KazNU), Kazakhstan. The Workshop intended to highlight the issues/problems related to the maintenance of scientific engineering equipments used in universities, research institutions and small scale industries. Two experts from Pakistan provided hands-on training to the participants of the workshop. Based on the list of instruments provided by host institute, technical program (Annexure-A) was finalized in consultation with ISESCO. The workshop was jointly organized and sponsored by COMSATS, ISESCO and KazNU, Kazakhastan. Two technical experts from PCSIR Arif Karim and Mr. Pir Bukhsh Khan conducted the training workshop. It is anticipated that this workshop will strengthen the existing facility of instrumentation in Al-Farabi University especially for the repair & maintenance of sophisticated scientific instruments. This effort will lead to the development of indigenous capacity and thus to sustainable development and self reliance.

2

OBJECTIVES The major objectives are as under:

Developing indigenous capability or enhancing skills of repair and maintenance of scientific instruments in Kazakhstan.

Building and enhancing technical-soundness and understanding of the local user, operator or maintenance engineer to communicate with the manufacturer, supplier or principal for the troubleshooting of critical failures and day to day problems.

Updating participant’s knowledge with the cutting edge technologies in instrumentation. Establishing common platform for scientists, engineers, teachers, service technicians,

operators and industrialists so that they can share their experience and skills regarding use, care and maintenance for effective utilization of instruments.

OUTCOMES OF THE WORKSHOP There were 10-technical sessions in the 5-days workshop, i.e. 2-technical sessions per day (Annexure-A, page 4~6). The first half before lunch is the lecture session where participants were given lectures covering basic principle of instruments and its troubleshooting techniques. In the second half (practical session) participants were utilized for repair & maintenance of faulty instruments of different laboratories of Al-Farabi University. The participants were demonstrated various repair & maintenance techniques as presented in the lectures. Following are the main outcomes of the workshops:

# Activity Achievement/Output 1. Lectures Delivered 18 (detail on page: 4~6) 2. No. of Participants Trained 36 (detail on page-10) 3. No. of Equipment Covered for repair 20 (detail on page: 7~8) 4. No. of Equipment Repaired 14 (detail on page: 7) 5. No. of Equipment Diagnosed 6 (detail on page: 8)

RECOMMENDATIONS It is suggested to establish a central repair and maintenance center in Kazakhstan for

effective preventive maintenance and troubleshooting of sophisticated scientific instruments in various organizations. The centre will maintain an online resource/library of manuals and softwares related to equipment in Kazakhstan. An online discussion forum, webinar and training workshops may be organized to strengthen the existing facility and human resource.

In the present workshop, some of the participants have very good repair and maintenance skills; they may be utilized for re-conducting similar training workshops to disseminate experience and knowledge.

While purchasing valuable instruments, it is suggested to arrange two trainings, i.e. one for the operator (operational training) and second for the service engineer (hardware or repair training). One might have to pay extra for that, so should be finalized before the issuance of purchase order. This will be highly beneficial for the smooth running of your instruments.

It is highly recommended that the hardware manuals of sophisticated instruments must be arranged or procured with the instruments. It is commonly observed that the hardware or repair manuals are optional with the instruments and they are charged extra and sometimes

3

too high, but they are very much helpful for the smooth and trouble free running of instruments. It is, therefore advised to make provision for their purchase with the instruments.

FUTURE ACTION PLAN Utilizing the local experts or trained-participants, a similar workshop may be arranged as a follow up. Al-Farabi University may be the best place for such workshops. This will greatly help in training and encouraging the young blood to join the field of instrumentation, thus strengthening the existing infrastructure of instrumentation in Kazakhstan. . In addition to these instruments on which training was delivered, experts can also impart trainings on repair and maintenance of other high-tech scientific instruments like Electron Microscopes, PCR, Emission Spectrograph, XRD, XRF, Liquid Nitrogen/Helium Plant, Laboratory Centrifuges etc. In this way, sharing of knowledge and experience will enhance the indigenous skills, potential and vision.

CONCLUSION The efforts of COMSATS, ISESCO and Alfarabi University of Kazakhstan concluded with great results in terms of participants trained and instruments covered. Around 36Nos. of participants were trained for repair and maintenance of various scientific instruments (Annexure-C, page-10) and around 18 instruments (Annexure-A, page-10) were covered for training in the workshop. In the practical session, participants were utilized for troubleshooting problems in 20Nos. of faulty instruments (Annexure-B, page: 7~9). 14 instruments were successfully made operative, while, for the other 6 Nos. of instruments, the faults were diagnosed; the problem was traced and pointed out to their engineers / technicians. This workshop is a good initiative for Alfarabi University Kazakhstan for the capacity building in the field of instrumentation especially for its repair & maintenance. Such workshops may further be organized and conducted with the existing local trained personnel, thus leading to the enhancement of indigenous manpower and skills.

Annexure A: Program Schedule

4

PROGRAM SCHEDULE National Workshop on Repair and Maintenance of Scientific Equipment in Universities,

Research Institutes and Small Scale Industries”, Kazakhstan, KazNU (October 2-6, 2017)

Inaugural Session (Location – Al-Farabi Scientific Library) 09:00-09:15 09:15-09:20 09:20-09:35 09:35-09:50 09:50-10:05 10:15-10:30 10:05-10:30

Guest to be seated Starting Prayer /Recitation of Holy Quran Welcome Address by Al-Farabi KazNU Representative Message from ED-COMSATS by COMSATS Representative Message from DG-ISESCO by ISESCO Representative Keynote Address by Chief Guest Refreshments

Technical Session – 1 (Lecture Session) (Location – Al-Farabi Scientific library) Day-1 10:30 General Repair & Maintenance Techniques (1- hours)

by Arif karim 11:30 General Repair & Maintenance Tools (1- hours)

by Pir Bukhsh khan 13:30 Lunch / Prayer break Technical Session – 2 (Practical Session) 14:30 Repair & Maintenance of Existing Equipments Physical-Technical Faculty, 222-cabinet 18:30 1st Day Concluding Session Technical Session – 3 (Lecture Session) (Location – Al-Farabi Scientific library) Day-2 9:00 Spectrophotometer Systems & Trouble Shooting Techniques (2-hours)

by Pir Bukhsh khan 11:00 Tea break (30 minutes) 11:30 LC / HPLC Systems & Trouble Shooting Techniques (2-hours)

by Arif karim 13:30 Lunch / Prayer break Technical Session – 4 (Practical Session) 14:30 Repair & Maintenance of Existing Equipments

Research Institute for Problems of Ecology, 509-cabinet Research Institute for Problems of Biology and Biotechnology, 216-cabinet

18:30 2nd Day Concluding Session Technical Session – 5 (Lecture Session) (Location – Al-Farabi Scientific library) Day-3 9:00 Laboratory Reactor Systems & Trouble Shooting Techniques (1-hours)

by Pir Bukhsh khan 10:00 GC/MS Systems & Trouble Shooting Techniques (1-hours)

by Arif karim 11:00 Tea break (30 minutes) 11:30 AAS Systems & Trouble Shooting Techniques (1-hours)

by Arif karim 12:30 Potentiostat-Galvanostat & Trouble Shooting Techniques (1-hours)

by Pir Bukhsh khan

Annexure A: Program Schedule

5

Technical Session – 6 (Practical Session) 14:30 Repair & Maintenance of Existing Equipments

Center of Physico-Chemical Methods of Research and Analysis, 201-cabinet SRI for New Chemical Technologies and Materials, 302-cabinet

18:30 3rd Day Concluding Session Technical Session – 7 (Lecture Session) (Location – Al-Farabi Scientific library) Day-4 9:00 ICP-OES (Alloy Analyzer) & Troubleshooting Techniques (1-hours)

by Arif karim 10:00 Auto Distillation Unit & Trouble Shooting Techniques (1-hours)

by Pir Bukhsh khan 11:00 Tea break (30 minutes) 11:30 Mass Spectrometer (MS) & Troubleshooting Techniques (1-hours)

by Arif karim 12:30 Galvanostat and Potentiostat (1-hours)

by Pir Bukhsh khan 13:30 Lunch / Prayer break Technical Session – 8 (Practical Session) 14:30 Repair & Maintenance of Existing Equipments

Faculty for Chemistry and Chemical Technology, 304-cabinet Faculty for Chemistry and Chemical Technology, 101-cabinet

18:30 4th Day Concluding Session Technical Session – 9 (Lecture Session) (Location – Al-Farabi Scientific library) Day-5 9:00 ICP-MS & Troubleshooting Techniques (2-hours) By Arif karim 11:00 Tea break (30 minutes) 11:30 Autoclave & Troubleshooting Techniques (2-hours)

by Pir Bukhsh khan 13:30 Lunch / Prayer break Technical Session – 10 (Practical Session) 14:30 Repair & Maintenance of Existing Equipments Faculty for Chemistry and Chemical Technology, 424-cabinet 18:30 5th Day Concluding Session

Concluding Ceremony (Location – Al-Farabi Scientific library)

16:30 Guest to be seated Starting Prayer / Recitation of Holy Quran Speech by Al-Farabi KazNU Representative Speech by COMSATS representative Speech by Chief Guest Participants Comments Distribution of Certificates Closing Remarks & Vote of Thanks

17:40-18:00 Refreshment

Annexure B: List of Instruments

6

List of Instruments Repaired / Fault Diagnosed

# Instrument Name/ Model

Worth (USD) Approx.

Problems Reported

Repair Work Carried Out

Final Status

1. Spectrophotometer Lambda 35, PerkinElmer

6,000 Out of order After thorough checking it was found that its calibration was not done / expired. The instrument has been recalibrated and it was made operative.

Made operative

2. Auto Distillation Unit (ADU-4)

15,000 No response There was no software communication with the instrument. Its computer has been repaired, Serviced and made operative.

Made operative

3. Laboratory Reactor LR-2/ST (Germany) UNIZIK

4,000 Agitator Fault

It was thoroughly checked, serviced and made operative.

Made operative

4. FTIR Systems CM1201

15,000 No communication with PC

It was thoroughly checked and serviced. The communication parameter was established and made operative.

Made operative. Need calibration.

5. Liquid Chromatograph

15,000 Vacuum Degasser problem

It was thoroughly checked; two of the vacuum pumps were serviced and made operative. The degasser chambers and pipes were found blocked due to deposition. One of the chamber was successfully cleaned and there engineers were asked to do the same for the rest of the three chambers.

Two of the vacuum pumps and a degasser chamber were successfully made operative.

6. FTIR Systems FSM

15,000 Out of order, Sample Cabinet was broken,

Serviced and made operative. Sample press rod was broken it can be easily fabricated from the market or replaced with new one. Measurement of the rode has been made, and if require can be fabricated in PCSIR-labs.

Made operative. Need replacement of sample preparation rod.

7. Spectrophotometer Shimadzu UV 3600

20,000 Out of order After thorough checking it was found that the life of D2 lamp and the tungsten lamp has been expired. The lamps need to be replaced.

Problem diagnosed need replacement of lamps.

8. Highly effective liquid chromatography (HELC) SYCAM

25,000 Completely dead

After thorough checking, the problem was found in the Refractive-Index detector. It was opened and hardware was

Problem diagnosed need replacement of lamps

Annexure B: List of Instruments

7

serviced. The lamp of the RI-detector was found deteriorated and need to be replaced.

9. Alloy analyzer (spectrometer) Agilent 725

100,000 Noise in the signal.

The instrument was checked and it was found that the nebulizer, spray chamber and the ICP-Torch require cleaning. Due to shortage of time the user/operator was given videos and guideline for cleaning and servicing.

Problem diagnosed, needs cleaning of sample introduction system and ICP torch.

10. ICP-MS Agilent 7500, USA

150,,000 Vacuum takes too long to achieve.

The instrument was thoroughly checked, the problem was found in the operation. Due to shortage of time the operator was given guide lines as under: The equipment need to

continuously be switched on or keep in standby mode, i.e. such instruments are not usually shutdown, and when they are shutdown , they took several hours to achieve good vacuum.

Use rotary-vacuum pump ballasting at least once in a week to remove any solvent present in the oil. This will increase the vacuum speed.

Problem is in the operation, the operator was given guide lines for proper operation.

11. IR-spectrometer Nicolet IR200

15,000 Completely dead

Software was reinstalled, serviced and made operative. Its moving mirror was damaged it need to be replace.

Problem diagnosed need replacement of` mirror.

12. Mass Spectrometer / Chromatech-crystal 5000

10,000 Completely dead

After thoroughly checking it was found that the main power supply card is faulty and some of the components were missing. In addition, SIL-connectors were found damaged. They were asked to arrange the missing components and repair the SIL-connectors.

Problem diagnosed need replacement of electronic components.

13. Auto Distillation Unit

10,000 Sensor Error The error was due to the improper installation. The operator was new to it. Due to shortage of time he was given guide lines for proper connection of pipes and filling of internal container/vessel.

Problem diagnosed requires proper connection of pipes and filling of containers.

Annexure C: List of Instruments

8

List of Participants “National Workshop on Repair and Maintenance of Scientific Engineering Equipments in Universities, Research Institutions and Small Scale Industries”, 2-6 October, 2017, Location: Al-Farabi, KazNU, Almaty, Science Library # Full Name Position Organization 1. Kuznetsov A.T. Leading Specialist Faculty of Chemistry and Chemical

Technology 2. Tursynbek S. PhD – 2 course Department of Chemistry and

Chemical Technology 3. Kasabekova J.A. Leading Specialist Department of Chemistry and

Chemical Technology 4. Nurgalimov B.N. Leading Specialist Department of Chemistry and

Chemical Technology 5. Shingisova R.D. Leading Specialist Department of Chemistry and

Chemical Technology 6. Azhigulova R.N. Senior teacher Department of Chemistry and

Chemical Technology 7. Kubasheva J.B. Leading Specialist Department of Chemistry and

Chemical Technology 8. Imangaliyeva

A.N. Teacher Department of Chemistry and

Chemical Technology 9. Dobzhinetskaya

V.L. Leading Specialist Department of Chemistry and

Chemical Technology 10. Dalibay A. Master of 1 course Department of Chemistry and

Chemical Technology 11. Seisembekova

A.B. PhD – 1 course Department of Chemistry and

Chemical Technology 12. Konuspaev S.R. Director of LLP «Sterin»

Innovation Company» Department of Chemistry and Chemical Technology

13. Kalugin S.N. Assistant professor Department of Chemistry and Chemical Technology

14. Myltykbayeva Zh.K.

Deputy Dean on Scientific and Innovation Work and International Relations

Department of Chemistry and Chemical Technology

15. Karagulanova A.S.

Leading Specialist, PhD, 1-course

Department of Science and Innovation, Department of Chemistry and Chemical Technology

16. Utegenov A. Scientific Researcher SRI of Experimental and theoretical physics

17. Ussenov Y. Deputy Director National Nanotechnology Open Laboratory

18. Batryshev D. Head Laboratoty of engineering profile al-Farabi KazNU

19. Shekerbaev K.S. Scientific Researcher National Nanotechnology Open Laboratory

20. Sagidolda Y. Deputy Head of Department for Science, Innovation work

Department of Physics and Technology

Annexure C: List of Instruments

9

and International Relations 21. Issanova M. Deputy Dean on Research

Activities & International Affairs

Department of Physics and Technology

22. Muratov M. Director National Nanotechnology Open Laboratory

23. Baimuldina N. Senior lecturer Department of Mechanics and Mathematics, Computer Science

24. Baubekova A.S. Deputy Dean on Scientific and Innovation Work and International Relations

Department of Biology and Biotechnology (KazNU)

25. Akhmetova A.B. Candidate of biological sciences, the teacher of department of botany and ecology

Department of Biology and Biotechnology (KazNU)

26. Shymshykov B.E. Lecturer Department of Biology and Biotechnology (KazNU)

27. Akhmetkaliyeva B.E.

Master student Department of Biology and Biotechnology (KazNU)

28. Abylaikhanova N. Candidate of Biological Sciences

Department of Biology and Biotechnology (KazNU)

29. Tastambek K. PhD, 1-course Department of Biology and Biotechnology (KazNU)

30. Kosalbayev B. PhD, 1-course Department of Biology and Biotechnology (KazNU)

31. Sokolov Yu.A. Senior Researcher Center of Physico-Chemical Methods of Research and Analysis

32. Bektassov M. Junior Researcher Center of Physico-Chemical Methods of Research and Analysis

33. Derbissalin М. Junior Researcher Center of Physico-Chemical Methods of Research and Analysis

34. Kenesov B.N. Professors Center of Physico-Chemical Methods of Research and Analysis

35. Temirbayeva K.A.

Vice-Dean on Scientific and Innovation Work and International Relations

Department of Geography and Environmental Sciences

36. Kozhakhmetov B.T.

Senior Lecturer The Department of Geography, Land Management and Cadastre (KazNU)

37. Zhalgasbekov Y.Zh.

Lecturer The Department of Cartography and Geoinformatics (KazNU)

38. Mukaliev Zh.K. Lecturer The Department of Geography, Land Management and Cadastre (KazNU)

39. Bekkuliev A. A. Lecturer The Department of Geography, Land Management and Cadastre (KazNU)

40. Sarybaev E.S. Senior lecturer The Department of Cartography and Geoinformatics

41. Satarbayeva A.S. Senior lecturer The UNESCO Chair for Sustainable Development

Annexure C: List of Instruments

10

42. Plokhikh R.V. Doctor of geographical sciences, acting Professor

The Department of Recreational Geography and Tourism

43. Sapiyeva A.Zh. Assistant The Department of Recreational Geography and Tourism

44. Minzhanova G.M.

Candidate of Geographical Sciences, Acting Assistant Professor

The UNESCO Chair for Sustainable Development

45. Issanbekova A.T. PhD, Senior Lecturer The UNESCO Chair for Sustainable Development

46. Nyssanbayeva A.S.

Vice Head on Scientific and Innovation Work and International Relations

The Department of Meteorology and Hydrology

47. Ibrayev B.M. Executive Director for Research and Cooperation

JSC «M. Tynyshpayev Kazakh Academy of Transport and Communications»

48. Alzhanuly B. Senior Specialist of the Research Centery

Eurasian Technological University

49. Kurmangaliyev M. Zh.

Head of the Engineering and Laboratory Complex

Caspian Public University

50. Kuldybaev N.M. Junior researcher Kazakh National Agrarian University 51. Rahman D. Senior Assistant Kazakh National Agrarian University

Participants from Non-Almaty Universities 52. Moldakhmetov

M.M. Deputy Director of the Agro-Bio Research Institute of the Ministry of Education and Science of the Republic of Kazakhstan

53. Mahmudova L.K. Head of the Department of Geography and History Taraz University of Innovation and Humanities

54. Rakhimov R.V. chief specialist of the Research and Production Center "ENU-Lab" of Eurasian National University, Astana

55. Saltayev A.K. laboratory assistant of the highest category of the laboratory maintenance branch of Eurasian National University, Astana

56. Sagituly R. Head of the Laboratory Services Branch of Eurasian National University, Astana

57. Baibazarova E. Master of Chemistry, lecturer of M.Kh.Dulati Taraz State University 58. Kenzhina I. Junior researcher 59. Omarov E.A. Engineer LIP Kyzylorda State University. Korkyt Ata 60. Karkynbekuly N. Specialist of mathematics faculty

Annexure D: Program Brochure

11

Annexure E: Picture Gallery

12

Picture Gallery

Inaugural Ceremony:

Inaugural Ceremony, Science Library Farabi University, Kazakhstan

Lecture Session:

Annexure E: Picture Gallery

13

Lecture Session, Science Library Farabi University, Kazakhstan

Practical Session:

Troubleshooting of Faulty Instruments

Annexure E: Picture Gallery

14

Concluding Ceremony: