Operating Procedure · Web viewThis procedure contains the step-by-step instructions required to safely and properly perform a routine sanitization of the SCSPF UPW system. A separate

TD / Process Engineering Specification # 5520-OP-464150July 26 ,2018

Rev. None

Fermi National Accelerator LaboratoryBatavia, IL 60510

SCSPF Maintenance Procedure - Ultra Pure Water System Sanitization Procedure

Date Organization ExtensionPrepared by:

Timothy McKennaTD/PE X5563

Reviewed by:

Chris BakerTD/SRFDD 630.252.5363

Approved by:

Damon BiceTD/SRFDD X2569

SCSPF UPW SANITIZATION PROCEDUREPage 1 of 14

Timothy R. Mckenna x5563 31310C, 07/26/18,

Timothy R. Mckenna x5563 31310C, 07/26/18,


Rev. NoneRevision Page

Revision Step No. Revision Description DateNone N/A Initial Release 05/30/2018



Rev. NoneTable of Contents

1.0 Purpose………………………………………………………………………………………………………..pg 4

2.0 Scope..................................................................................................................................................................pg 4

3.0 Responsibilities..................................................................................................................................................pg 4

4.0 Safety..................................................................................................................................................................pg 4

5.0 Training needs....................................................................................................................................................pg 5

6.0 Required Materials.............................................................................................................................................pg 5

7.0 Procedures………………………………………………………………………….………………………....pg 5

8.0 Importance of Compliance.…………………………………………………………………………………pg 14



Rev. None

1. PURPOSE:

This document describes the procedure to sanitize the ANL SCSPF UPW system.

2. SCOPE:

This procedure contains the step-by-step instructions required to safely and properly perform a routine sanitization of the SCSPF UPW system. A separate section describes the procedure to sanitize the high-pressure rinse leg of the UPW system.

The following items are included in this document:

a. Personnel Responsibilitiesb. Safetyc. Training Requirementsd. Required Materialse. Standard UPW Sanitization Proceduref. High-pressure Rinse Leg Sanitization

3. RESPONSIBILITIES:

The scientist in charge of the SCSPF is responsible for ensuring that all activities related to the UPW system sanitization are in compliance with the ANL ES&H requirements including, but not limited to, the ANL Phys. Div. Chemical Hygiene Plan.

The operating technicians are responsible for following this procedure as written. The scope of the activities fall within the standard limits as set out by the ANL Phys. Div. chemical hygiene plan.

4. SAFETY:

4.1. The MSDS’s for both Minncare Cold Sterilant and Ethyl Alcohol should be reviewed by each operating technician

4.2. The following PPE must be worn by all operating technicians during the procedure:4.2.1. Safety glasses4.2.2. Nitrile gloves4.2.3. (other---check MSDS for Minncare)



Rev. None4.3. Gloves (nitrile or latex) and safety glasses should be worn at all times due to the

use of Ethyl Alcohol, Minncare, compressed air, etc.4.4. Contact ANL Cleanroom Manager or ANL safety representative for any additional

questions or concerns.

5. TRAINING NEEDS:

Who: Any Cleanroom Technician assigned to perform the UPW sanitization.How: Review of document followed by peer training.

6. REQUIRED MATERIALS:

6.1. Safety glasses6.2. Safety face shield6.3. Full length plastic chemical apron6.4. Nitrile gloves6.5. Butyl gloves6.6. Ethyl Alcohol in approved dispenser6.7. WypAll wipes6.8. Minncare 1% test strips6.9. Minncare Residual test strips (evidence strips)6.10. (9) 1 gal. Minncare Cold Sterilant (this is minimum amount needed)6.11. (2) new DI Express resin mixbed final polish tanks (to be delivered by Crossbow

the day of the sanitization - they should have been recharged the day before)6.12. (1) new DI Express resin mixbed MAIN tank (to be delivered by Crossbow the

day of the sanitization – it should have been recharged the day before)6.13. (7) 0.2µm final filters (from Crossbow)6.14. (7) 0.05µm final filters (from Crossbow)6.15. (1) 0.05µm filter for HPR wand (Pall T8810006300)6.16. (1) 0.04µm filter for post HPR pump housing (Parker ZCPSA-004Z-P)6.17. (3) Drain/rinse hoses with connectors (these have special fittings that connect to

the resin tanks, the DI holding tanks and to each other)

7. PROCEDURE:

Preparation

7.1. Perform the standard bacteria test so that we have pre and post sanitization bacteria samples



Rev. None7.2. NOTE: IF ONLY SANITIZING THE HIGH PRESSURE SIDE (HPR supply),

PROCEED TO “Sanitization – High Pressure Side (HPR supply only)”7.3. Call Crossbow to order fresh DI bottles to be delivered the day of the sanitization7.4. Isolate the TOC monitor

7.4.1. Unplug the power supply from the TOC monitor7.4.2. Close the water supply valve that supplies water to the TOC monitor7.4.3. Disconnect water line on side of TOC monitor

7.5. Close HPR water valves (ONLY if not sanitizing the high pressure leg)7.6. Close the valve that supplies water to the EP/BCP rooms (this is necessary to

isolate the EP room from the Minncare so as not to contaminate the EP supply tank and system)

Sanitization – DI Tanks, Entire System (including high pressure side)

7.7. Turn RO system to “Off” through RO graphic screen control

7.8. Turn distribution pump switch to “Off” through power panel (located close to final filter housings)



Rev. None

7.9. Close the 2 valves located on either side of the final filter housings7.10. Change out the final polish filters

7.10.1. Release the pressure on the 2 final filter housings via the pressure relief valves on top of the housings

7.10.2. Don Nitrile gloves7.10.3. Change all final filters out (changing now sanitizes filters and prevents

possible contamination of filters from handling)7.10.3.1. (7) 0.2µm final filters7.10.3.2. (7) 0.05µm final filters

7.11. Change HPR filters (at wand and after HPR pumps)7.11.1. (1) 0.05µm filter for HPR wand (Pall T8810006300)7.11.2. (1) 0.04µm filter for post HPR pump housing (Parker ZCPSA-004Z-P)

7.12. Take the 2 DI Express final polish resin mixbed tanks out of the loop7.12.1. Jumper the 2 tank lines together by connecting them to each other

7.13. Open the 2 valves located on either side of the final filter housings7.14. Turn distribution pump switch to “On”7.15. Change out the HPR filters

7.15.1. Close the HPR water supply valve that supplies water to the HPR wand (ball valve located in the Anteroom)



Rev. None

7.15.2. Close the DI supply valve on the high pressure side (located close to DI storage tank #1)

7.15.3. Change out the HPR pre-filter (located near the HPR pumps)



Rev. None

7.15.4. Change out the HPR filter (located beneath the HPR wand)

7.15.5. Open the HPR water supply valve that supplies water to the HPR wand7.15.6. Open the DI supply valve on the high pressure side

7.16. If not already installed, install drain line from DI storage tank #1 to floor drain

7.17. Drain all tanks down to ¾ (~300 gallons left in each 400 gallon tank)7.17.1. For tank #1, use tape to hold switch open labeled “Hi Limit Test” on Ryan’s

tank overflow controller7.18. Turn distribution pump switch to “Off”7.19. Don Butyl gloves (over Nitrile), face shield and apron7.20. Add 1% Minncare Cold Sterilant (3 gal. – 1 gal. Minncare for each 100 gal. of

water) to the top of each DI supply tank (via the large screw cap on top of tank)SCSPF UPW SANITIZATION PROCEDURE

Page 9 of 14


Rev. None7.21. Turn distribution pump switch to “On”7.22. Let Minncare circulate in system for 30 minutes7.23. Using 1% Minncare test strips, test the last DI water drop7.24. If 1% is present, check all drops

7.24.1. HPR wand7.24.2. Large US tank fill line7.24.3. Small US tank fill line7.24.4. Small US tank sprayer7.24.5. EP room sprayer7.24.6. Bacteria sampling test port

7.25. If 1% is not present at all drops, continue to circulate system and check again every 10 minutes

7.26. Once all drops show presence of 1% Minncare, actuate all valves, drops, etc. in the entire DI system to make sure the Minncare has seen every part of the system

7.27. Switch over DI supply in anteroom to ANL cleanroom and run through their wand until 1% Minncare is present

7.27.1. Then switch water back over to FNAL side7.28. Run hand HPR in ANL cleanroom until 1% Minncare is present7.29. Turn distribution pump switch to “Off” and let system “sit” for at least 1 hour

(Leave HPR supply valve open)

Drain, Flush and Cleanup

7.30. Turn distribution pump switch to “On”7.31. Drain all 3 DI storage tanks

7.31.1. Hook up all the drain/rinse hoses to the drain of DI storage tank #1 during draining (this will clean the hoses prior to their use in rinsing the tanks)

7.31.2. Open the fill lines in Anteroom to speed up the draining process7.31.3. Leave HPR supply valve open7.31.4. When storage tanks get down to ~15%, turn RO system to “On” (this will

introduce fresh water to system to help flush it out)7.31.5. Turn RO system to “Off” when storage tanks reach ~5%7.31.6. When storage tanks are almost empty, turn distribution pump switch to “Off”



Rev. None7.31.7. Hook up one of the sanitized drain lines up to the RO system bypass (“T”

that is installed next to the Carbon and Softguard tanks)

7.31.7.1. Use this valve as an ON/OFF control for flow of water during rinsing/filling

7.31.7.1.1. Open valve that is above the “T” valve (“System Bypass Valve” as seen in above picture), this will give higher pressure through hose when rinsing tanks

7.31.8. Hook other end of hose to the “I” (IN) on the MAIN style resin mixbed tank supplied by Crossbow

7.32. Hook up the other sanitized drain line to the “O” (OUT) of the mixbed tank7.32.1. Remove the lines coming off of the mixbed tanks and couple them together

7.32.2. This will be your storage tank rinsing/filling hose7.32.3. Install the custom made “spray nozzle” to the end of this hose to assist with

tank rinsing7.32.3.1. FYI, this water is coming from the softener and then being cleaned by

the mixbed tank (it has NOT been RO’d)7.33. Run water through this line to the drain for a few minutes to rinse out the mixbed

tank7.34. Rinse out all 3 DI supply tanks

7.34.1. Shutoff bottom valves on tanks 1 and 2 (to keep rinse water from tank 3 backing up inside those tanks)

7.34.2. Shutoff the loop valves at top of tanks 1, 2, and 3(again, to keep Minncare treated water out of tanks that are being rinsed)



Rev. None7.34.3. Begin rinsing out storage tank #3, top to bottom, via the large screw cap at

top

7.34.3.1. Rinse tanks for ~15 minutes each7.34.4. After tank #3 is rinsed, close valve at bottom of tank, open valve at bottom

of Tank #2 and proceed to rinsing tank #27.34.5. After tank #2 is rinsed, close valve at bottom of tank, open valve at bottom

of Tank #1 and proceed to rinsing tank #17.34.6. Once rinsed, turn RO system back on while simultaneously filling with the

rinse line (to fill tank faster)7.34.6.1. Distribution pump may need to be “burped” due to air in line

7.34.6.1.1. Do this by loosening the “burp” bolt on the “T” at the bottom of the dist. Pump housing

7.34.7. Once tank #1 is ~5% full, turn distribution pump switch to “On” and continue rinsing/filling tank #1

7.34.7.1. This will begin rinsing out the loop7.34.8. After ~15 minutes of this, begin checking the drain water again for Minncare

residual7.34.9. Once that looks good, begin checking the Anteroom and other upstairs

drops7.34.9.1. Continue this until all drops show only a slight presence of Minncare

(1-3 on scale)7.34.10. Allow tank #1 to fill a bit7.34.11. Hook up drain hose to the recirculation loop tap located at the top of tank

#3 and run to floor drain



Rev. None

7.34.11.1. This will flow water through the loop, through the hose and to the drain and will aid in the thorough rinse out of the loop

7.34.12. Check all drops for Minncare residual7.34.12.1. HPR wand can still show a slight presence as this leg will continue to

purge itself7.34.13. Actuate all valves/drops7.34.14. Disconnect drain hose from top of tank #37.34.15. Turn recirculation valves on the top of all tanks to 45°7.34.16. Make sure drain valves at the bottom of tanks #2 and #3 are open7.34.17. Close drain valve on tank #1

7.35. Turn distribution pump switch to “Off”7.36. Close water valve to final polish tanks7.37. Install new DI Express final polish resin mixbed tanks that were supplied by

Crossbow

7.38. Open water valve to final polish tanks7.39. Turn distribution pump switch to “On”7.40. Make sure RO system is “On”7.41. Let system generate new DI water and fill tanks7.42. Verify that RO system is cycling on and off at the proper tank levels (that tank

does not overflow, etc.)7.43. Verify that all Megohm monitors are reading at 18 or above (RO, primary, loop,

polishing)SCSPF UPW SANITIZATION PROCEDURE

Page 13 of 14


Rev. None7.44. Turn TOC monitor back on and supplying water valve7.45. Switch over DI supply in anteroom to ANL cleanroom and run through their wand

until NO Minncare is present7.45.1. Then switch water back over to FNAL side

7.46. Run hand HPR in ANL cleanroom until NO Minncare is present7.47. Remove tape from switch of Ryan’s automatic tank overflow drain system from

bottom of storage tank 1, reset this system and verify operation

Sanitization – High Pressure Side (HPR supply only)

8. IMPORTANCE OF COMPLIANCE:8.1. Compliance with this policy helps provide the highest quality safety protection for

the employees who attempt to perform the UPW sanitization. Violations of this policy will be considered misconduct related to a safety policy and can result in disciplinary action up to and including termination of employment.


Documents

Operating Procedure · Web viewThis procedure contains the step-by-step instructions required to safely and properly perform a routine sanitization of the SCSPF UPW system. A separate