Petro Rabigh: PMMA-Residual Monomer Work Instruction (PDF)

Petro Rabigh: Rabigh Refining & Petrochemical Company Work Instruction PMMA-Residual Monomer Quality Control Department Engineering & Support Issuing Organization QCD Polymer II Section Document No. Revision No. Effective Date PR/QCD/QCP2/WI-307 01 11/20/2022 Description Name Job Title...

Petro Rabigh: Rabigh Refining & Petrochemical Company Work Instruction PMMA-Residual Monomer Quality Control Department Engineering & Support Issuing Organization QCD Polymer II Section Document No. Revision No. Effective Date PR/QCD/QCP2/WI-307 01 11/20/2022 Description Name Job Title Date Signature Initiated By THAKKAR, RAKESHKUMAR P. Senior Chemist, QCD Polymer II Section 11/14/2022 Signed Reviewed By Rajab, Muhammad Hasbi J. Section Head,QCD Polymer II Section 11/17/2022 Signed Manager,Quality Control Department 11/20/2022 Signed Approved By Ghanemi, Adil I. Confidential Government Confidential Page 1 Restricted Company General Use Work Instruction PMMA-Residual Monomer Engineering & Support Quality Control Department Issuing Organization QCD Polymer II Section Document No. Revision No. PR/QCD/QCP2/WI-307 01 Effective Date 11/20/2022 Table of content 1. Purpose .............................................................................................................................................. 3 2. Scope.................................................................................................................................................. 3 3. Abbreviations, Acronyms and Definitions ........................................................................................ 3 4. Responsibilities / Impacted............................................................................................................... 4 5. Process / Instruction Description...................................................................................................... 4 6. Process / Flow Chart.......................................................................................................................... 6 7. Forms for Records ............................................................................................................................. 6 8. References ......................................................................................................................................... 7 9. Document History ............................................................................................................................. 7 10. Annexure ........................................................................................................................................ 8 Page 2 Work Instruction PMMA-Residual Monomer Engineering & Support Quality Control Department Issuing Organization QCD Polymer II Section Document No. Revision No. PR/QCD/QCP2/WI-307 01 Effective Date 11/20/2022 1. Purpose This work instruction describes how to determine residual monomer concentration in PMMA. 2. Scope This work instructions is applicable for PMMA pellets sample. 3. Abbreviations, Acronyms and Definitions 3.1 Abbreviations: Abbreviations Description g gram mL mililitre MA Methyl Acrylate MMA Methyl methacrylate MIK Methyl iso-butyl ketone 3.2 Acronyms: Acronyms Description LIMS Laboratory Information Management System MSDS Material Safety Data Sheet QCD Quality Control Department SSV Shift Supervisor SH Section Head Page 3 Work Instruction PMMA-Residual Monomer Engineering & Support Quality Control Department Issuing Organization QCD Polymer II Section Document No. Revision No. PR/QCD/QCP2/WI-307 01 Acronyms Description DSV Day Shift Supervisor Effective Date 11/20/2022 3.3 Definitions: 4. Responsibilities / Impacted 4.1 QCD Polymer Section, Section Head 4.1.1. Section Head is responsible to review the document and ensure it is up to date. 4.2 QCD Polymer Section, Chemist 4.2.1. Chemist is responsible to ensure the communication, training and implementation of the work instruction within the section. 4.3 QCD Polymer Section, SSV/DSV 4.3.1. SSV/DSV is responsible to monitor the proper implementation of the work instruction within the section and report any related issues to SH or Chemists. 4.4 QCD Polymer Section, Laboratory Technician 4.4.1. Laboratory technician is responsible to perform the analysis as per work instruction and proper housekeeping after completing the analysis. 5. Process / Instruction Description Overview A. Summary Concentration of MMA monomer and methyl acrylate concentration are determined with gas chromatography according to the internal standard method using methyl isobutyl ketone as the internal standard substance. B. Safety Use Safety glass, Nitrile gloves and safety shoes Methyl iso-butyl ketone: Keep away from sources of ignition. Avoid contact with skin and eyes Page 4 Work Instruction PMMA-Residual Monomer Engineering & Support Quality Control Department Issuing Organization QCD Polymer II Section Document No. Revision No. PR/QCD/QCP2/WI-307 01 Effective Date 11/20/2022 Methyl methacrylate: Avoid contact with skin and eyes. Avoid inhalation of vapor. Keep away from sources of ignition Methyl acrylate: Keep away from heat. Keep away from sources of ignition. Acetone: Keep away from sources of ignition. Methanol: Keep away from sources of ignition. C. Apparatus Gas Chromatograph : Agilent (7890 B) with FID detector D. Reagents Methyl Isobutyl Ketone : Reagent (special grade) MMA Monomer : Reagent (special grade) Methyl Acrylate : Reagent (special grade) Methanol : Reagent (special grade) E. Calibrations -Equipment Calibration is conducted by Chemist following below steps. -Prepare below solutions-Mother Solution: Take 0.3 g MA + 0.3 g MMA in 50 mL flask and make up to 50 mL by Methanol. -Solution A : Take 1.25 mL mother solution in 25 mL flask, add 0.015 g MIK and make up to 25 mL by Methanol. -Solution B: Take 2.5 mL of mother solution in 25 mL flask, add 0.015 g MIK and make up to 25 mL by Methanol. -Solution C: Take 5 mL of mother solution in 25 mL flask, add 0.015 g MIK and make up to 25 mL by Methanol. -Solution D: Take 10 mL of mother solution in 25 mL flask, add 0.015 g MIK and make up to 25 mL by Methanol. -Fill solution A, B, C and D in 2 mL vial. -Inject standard solutions A, B, C and D (2.0 µl each) into the stabilized gas chromatograph using Auto sampler. -The response factor will be automatic calculated by software. Page 5 Work Instruction PMMA-Residual Monomer Engineering & Support Quality Control Department Issuing Organization QCD Polymer II Section Document No. Revision No. PR/QCD/QCP2/WI-307 01 Effective Date 11/20/2022 Responsibility Org Sr. No. Process / Instruction Description Position 5.1. Take 2.5 g of PMMA in a 50 mL Duran laboratory bottles and QCD Polymer II note down the exact weight. Section Lab Technician 5.2. Take 10 mL of acetone by pipette and transfer it to the sample bottle and immediately close bottle with cap. QCD Polymer II Section Lab Technician 5.3. Keep sample bottle on stirrer and stir for 8 hours or until polymer completely dissolved. QCD Polymer II Section Lab Technician 5.4. Add 0.030 g of MIK (internal standard) using micro syringe and note exact weight. QCD Polymer II Section Lab Technician 5.5. Add 30 mL of methanol for precipitation of polymer and close QCD Polymer II bottle with cap and mix well by shaking. Section Lab Technician 5.6. Leave sample bottle for 12 hours to settle polymer, after that take the supernatant liquid in syringe, connect with filter and transfer filtered liquid to 2 mL GC vial. Keep the GC vial in GC sample holder. Select Method “Residual monomer”, Load sequence “Residual monomer” and Feed sample ID, sample weight, internal standard weight and press run. Note the result from chromatogram at the end of analysis. QCD Polymer II Section Lab Technician QCD Polymer II Section Lab Technician QCD Polymer II Section QCD Polymer II Section QCD Polymer II Section Lab Technician QCD Polymer II Section Lab Technician 5.7. 5.8. 5.9. 5.10. Report the result rounded to two decimal place as residual monomer of sample in % and record the results in LIMS. Waste Disposal 5.11. Dispose waste sample to the appropriate waste container. Housekeeping After completing the analysis, perform the proper housekeeping in the area. 6. Process / Flow Chart This is not applicable 7. Forms for Records This is not applicable Page 6 Lab Technician Lab Technician Reference Work Instruction PMMA-Residual Monomer Engineering & Support Quality Control Department Issuing Organization QCD Polymer II Section Document No. Revision No. PR/QCD/QCP2/WI-307 01 Effective Date 11/20/2022 8. References S. No. Document Number Title / Description 1 OM-290-CH4-4-9 Residual Monomer in PMMA 9. Document History Revision No. 00 Revision Date 8/10/2017 Revision Summary First Issue. Approvals (By Name) Initiated By Aljahdali, Bassam. Chemist, QCD Polymer II. Yasunari Haishima. Chemist QCD Polymer II Reviewed By Rajab, Muhammad Hasbi J. Section Head, QCD Polymer II Section Concurred By Approved By Ghanemi, Adil I. Manager, Quality Control Department 01 11/20/2022 Review of document as per GI Initiated By (General Instruction) PR/PCO/CPM/GI-001 (Document and Record Reviewed By Management). THAKKAR, RAKESHKUMAR P. Senior Chemist, QCD Polymer II Section Rajab, Muhammad Hasbi J. Section Head,QCD Polymer II Section Concurred By Approved By Ghanemi, Adil I. Manager, Quality Control Department 01 11/20/2022 Review of document as per GI Initiated By (General Instruction) PR/PCO/CPM/GI-001 (Document and Record Reviewed By Management). THAKKAR, RAKESHKUMAR P. Senior Chemist, QCD Polymer II Section Rajab, Muhammad Hasbi J. Section Head,QCD Polymer II Section Concurred By Approved By Ghanemi, Adil I. Page 7 Work Instruction PMMA-Residual Monomer Engineering & Support Quality Control Department Issuing Organization QCD Polymer II Section Document No. Revision No. PR/QCD/QCP2/WI-307 Revision No. Revision Date 01 Effective Date 11/20/2022 Revision Summary Approvals (By Name) Manager, Quality Control Department 10. Annexure 10.1 GC Operation condition Column : DB-1 Length 30 m, Diameter 0.32 and film thickness 5 micrometer Column temperature 35 hold 10 Min, Rate-15oC/min 280oC, Hold 0 min. Injector : Injection volume 2μl, Temperature 310oC, Split ratio 1:50, Gas saver on 20 after 2 min Detector : FID, Temperature: 250oC, H2 Flow 45 ml/min, Air Flow 400 ml/min Page 8