General preventive Maintenance of HPLC

1.0 OBJECTIVE

1.1 To have a written procedure for the General preventive Maintenance of HPLC.

2.0 SCOPE

2.1 Applicable to the HPLC Instruments present in  analytical Laboratory to prevent the number of breakdowns and smooth running of the Instruments.

3.0 RESPONSIBILITY

3.1 In-House Service Engineer

4.0 ACCOUNTABILITY

4.1 Manager – Research and Development

5.0 PROCEDURE

5.1 Pre-requisites

5.1.1 Ensure the power supply, which meets specifications for the Instruments. 

5.1.2 Check the availability of necessary items for Preventive Maintenance of    Instruments.

5.1.3 Check the availability of personal protective equipment and wear the applicable, while doing the maintenance / cleaning of Instruments.

5.2 Special Precautions

5.2.1 Remove the spilled water (If present) on the instrument surface and do not use   alcohol or thinner type solvents to clean the surface. These can causes rusting and discoloration.       

5.3 General Maintenance and cleaning of HPLC:

5.3.1 Before performing the general maintenance, ensure the system is in Z- home. 

5.3.2 Before performing the general maintenance disconnect the power card from mains.

5.3.3 Move the INSTRUMENT carefully to outside of the lab, and remove the side back covers and clean the dust inside with air blower.

5.3.4 After cleaning ensure the covers are replaced to same position.

5.3.5 Perform the general Preventive maintenance as per the procedure, General Preventive maintenance will be performed according the schedule date.

5.3.6 After completion of general Preventive maintenance for each instrument, record the dates in the Instrument maintenance log sheet and Preventive maintenance Record (Annexure-III) and maintain the schedule (Annexure-II) 

5.3.7 Perform the breakdown maintenance/parts replacement as and when it is required and record the activity in the Instrument maintenance log sheet.

5.4 Procedure for Preventive Maintenance of HPLC:

5.4.1 Pump:

5.4.1.1 Remove the suction filters from flow lines and sonicate in 1M nitric acid. Boil for 10 minutes then sonicate with IPA, methanol and water.

5.4.1.2 Remove the Inlet and out let tubing from pumps. And flush with IPA, methanol and water.

5.4.1.3 Cleaning and Replacement of Outlet check valve and DIV Cartridge:

5.4.1.3.1 Using the M4 wrench provided, securely hold the   outlet check valve, using another wrench loose the SS tubing male nut and disconnect the SS tubing.

5.4.1.3.2 Remove the outlet check valve from the pump head.

5.4.1.3.3 Using the Wrench (12mm, thin type) loosen the nut and remove the dynamic inlet valve.

5.4.1.3.4 Remove the Check valve cartridge from Dynamic inlet valve. 

5.4.1.3.5 Place the outlet valve and the DIV cartridge in IPA, methanol and water and sonicate for 5 minutes. 

5.4.1.3.6 Record the details of any replacement of above parts in Instrument maintenance log sheet and Annexure-III.

5.4.1.4 Cleaning and Replacement of Plunger seal and Plunger: 

5.4.1.4.1 Before removing the plunger seals and plunger, Press Vp, F2 [MNTE] to open the parts replacement screen and enter the number 3 press Enter.

5.4.1.4.2 Select left or right plunger seals to replace. Use proper tools to remove the parts.

5.4.1.4.3 Remove the pump head, which is selected and inspect the seals and the plunger.

5.4.1.4.4 Clean the plunger with methanol and water and sonicate in methanol for 5 minutes. Replace the plunger if any scratches found in the surface

5.4.1.4.5 Replace the plunger seals every six months or as and when required.

5.4.1.4.6 Record the details of any replacement of above parts in Instrument maintenance log sheet and Annexure-III. 

5.4.2 Auto Sampler:

5.4.2.1 Cleaning and replacement of Needle seal :

5.4.2.1.1 Before removing the needle seal, Ensure the Needle is in Z- Home Mode.  

5.4.2.1.2 Remove the sample rack, loosen the panel screws and remove the panel.

5.4.2.1.3 Remove the injection port nut with the wrench, and remove the injection port sleeve, and remove the needle seal from the sleeve.

5.4.2.1.4 Clean the needle seal with methanol and water and sonicate in methanol for 5 minutes. Install the needle seal in the injection port sleeve and tighten the nut by hand first and then use the wrench -14 to tighten it an additional 90º.

5.4.2.1.5 Replace the needle seal every one year or as and when required.

5.4.2.1.6 Record the details of any replacement of above parts in Instrument maintenance log sheet and Annexure-III. 

5.4.2.2 Cleaning and Replacement of HPV and LPV  Rotors :

5.4.2.2.1 Before removing the HPV and LPV Assys Press Vp, F2 [MNTE] to open the parts replacement screen and enter the number 8 for HPV and number 7 for LPV then   press Enter.

5.4.2.2.2 Remove all of the flow line male nuts from the housing. Loosen and remove the three hex screws with M4 hex key.

5.4.2.2.3 Remove the stator assy and rotor seal, inspect the parts for visible nicks or scratches, clean the parts with methanol and water and sonicate for 5 minutes. Replace if rotor or stator is damaged.

5.4.2.2.4 Clean the rotor and stator every six months and replace every one year or as and when required.

5.4.2.2.5 Apply the same procedure for LPV maintenance and cleaning.

5.4.2.2.6 Record the details of any replacement of above parts in Instrument maintenance log sheet and Annexure-III.      

5.4.2.3 Cleaning and replacement of Measuring pump seal :  

5.4.2.3.1 Remove the SS tubing from measuring pump and loosen the hex screws and remove the head. Remove the seal from the seal holder.

5.4.2.3.2 Clean the plunger seal and sonicate for 5 minutes in methanol and water. 

5.4.2.3.3 After cleaning replace the seal to holder, and fit the pump head and tighten the hex screws with proper alignment.

5.4.2.3.4 After completion of maintenance fix the SS tubes to pump head.

5.4.2.3.5 Cleaning shall be done in every six months; the replacement shall be done in every one year.   

5.4.2.3.6 Record the details of any replacement of above parts in Instrument maintenance log sheet and Annexure-III.

5.4.3 Detector UV- VIS/PDA : 

5.4.3.1 Replacement of D2  Lamp:   

5.4.3.1.1 Before replacement of D2 Lamp Press Vp, F2 [MNTE] to open the parts replacement screen and enter the number 9 then   press Enter. Then turn off the power.  

5.4.3.1.2 Press down on the lever to detach the lamp cover, and detach the lamp connector.

5.4.3.1.3 Loosen the two lamp screws with a screwdriver and remove the lamp.

5.4.3.1.4 Replace the New lamp, and secure it with the screws and attach the lamp connector. 

5.4.3.1.5 Install the lamp cover and close the doors to the detector.

5.4.3.1.6 After replacing the lamp switch ON the instrument. Then press the enter key to reset the lamp hours.

5.4.3.1.7 Replace the lamp every six months or the acceptance criteria not met. (Energy not less than 800v).

5.4.3.1.8 Record the details of any replacement of above parts in Instrument maintenance log sheet and Annexure-III. 

5.4.3.2 Cleaning of Flowcell 

5.4.3.2.1 Disconnect the flow cell connector, and loosen the upper and lower side cell retaining screws, and remove the flow cell window.

5.4.3.2.2 Remove the left and right lens window screws. Remove the lens and gaskets from both sides of the cell. And clean the lens and sonicate for five minutes in an IPA.

5.4.3.2.3 After completion of cleaning reinstall the parts to same position.  

5.4.3.2.4 Replace the gaskets every one year, and clean the flow cell every six months or as and when required.

5.4.3.2.5 Record the details of any replacement of above parts in Instrument maintenance log sheet and Annexure-III.  

5.4.3.3 Replacement of W lamp(PDA): 

5.4.3.3.1 Before replacement of W lamp switch OFF power to the instrument and unplug the power cable.

5.4.3.3.2 Remove the two W lamp mounting screws, and remove the plate from the instrument.

5.4.3.3.3 Remove the W lamp from the plate, and install a new W lamp. Push the feet of the W lamp all the way to the base of the socket to fix it securely.

5.4.3.3.4 After replacing the W lamp, To reset the lamp usage time to 0, Start PDA utility, press Wavelength calibration button, and press [function]→[lamp time],Then reset the time hours.    

5.4.3.3.5 Replace the W lamp every six months or the acceptance criteria not met.

Check Criteria: Maximum Intensity around 400-800nm≥2.5V)

5.4.3.3.6 Record the details of any replacement of above parts in Instrument maintenance log sheet and Annexure-III.  

5.4.3.4 Replacement of D2 lamp(PDA): 

5.4.3.4.1 Before replacement of D2 lamp switch OFF power to the instrument and unplug the power cable.

5.4.3.4.2 Remove the two D2 lamp mounting screws, and remove the Lamp from the instrument.

5.4.3.4.3 Reinstall the D2 lamp assembly to its original condition in the instrument.

5.4.3.4.4 After replacing the D2 lamp, To reset the lamp usage time to 0, Start PDA utility, press Wavelength calibration button, and press [function]→[lamp time],Then reset the time hours.

5.4.3.4.5 Replace the D2 lamp every six months or the acceptance criteria not met.

Check Criteria: Maximum Intensity around 200-260nm≥3.5V)

5.4.3.4.6 Record the details of any replacement of above parts in maintenance log sheet and Annexure-III.  

6.0 ANNEXURES 

6.1 ANNEXURE-I: Instrument Maintenance Log Sheet. 

6.2 ANNEXURE -II: Preventive Maintenance Schedule. 

6.3 ANNEXURE -III: Preventive Maintenance Record.