Process Monitoring: Chemical and Mechanical Parameters

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Process Monitoring: Chemical and
Mechanical Parameters
To achleve process control for
Process E-6, you must monltor and
control the key process parameters.
Measurlng the key parameters and
plottlng the results on control charts
enables you to detect changes or
"out-of-control` condltlons before
they affect customer fllm or control
strlps. Vhen you detect a change,
lnvestlgate the cause and correct lt, lf
necessary. Vlth process control, you
vlll be able to ldentlfy and flx the
cause of the problem lnstead of |ust
compensatlng for the effect of lt.
As you monltor and control the key
parametersspeclflc gravlty, replen-
lshment rates, tlme, temperature,
reclrculatlon, agltatlon, and the
concentratlons of certaln chemlcal
componentsyou vlll contlnue to
use control strlps to ccnjirm that your
process ls ln control. For more lnfor-
matlon on uslng control strlps, see
Frcccss Mcnitcring: Scnsitcmctric
Fnrnmctcrs, Sectlon .
Process monltorlng ls a crltlcal step
tovard achlevlng optlmum control of
Process E-6 and malntalnlng the
process at an optlmum level.
Nov you are ready to follov these
steps:
l. Ellmlnate or mlnlmlze all sources
of oxldatlon
2. Ellmlnate or mlnlmlze evaporatlon
}. Begln process monltorlng
. Stablllze your process
. Ad|ust your process to alm
6. ptlmlze your process
7. Malntaln your process at an optl-
mum level
Explanatlons and procedures for
steps l through } are glven ln thls
sectlon, explanatlons and procedures
for steps through 6 are glven ln
Sectlon 6, and malntenance proce-
dures are glven ln Sectlon l6.
EIiminate er Minimize AII
5eurces e[ Oxidatien
xldatlon of chemlcals ln solutlons
can occur by aerlal oxldatlon and by
oxldatlon vlthln solutlons.
Vhenever a solutlon ls ln contact
vlth alr, aeriaI exidatien can occur.
Solutlons are sub|ect to aerlal oxlda-
tlon durlng processlng hours and
durlng non-processlng hours lf they
are kept ln tanks vlthout floatlng llds.
Oxidatien uithin seIutiens
occurs vhen alr or oxygen ls mlxed
lnto the solutlon. Thls can be caused
by a bad reclrculatlon pump (vlth a
leak that allovs alr to enter the llne),
a faulty fllter houslng, a lov solutlon
level that permlts alr to be sucked
lnto the reclrculatlon system, or poor
mlxlng procedures, such as over-
mlxlng and mlxlng too vlgorously.
To ellmlnate or mlnlmlze all
sources of oxldatlon, follov these
steps:
l. Use floatlng llds on all rack-and-
tank machlne tanksexcept the
bleach and flxervhen the process
ls not ln operatlon, as vell as on all
replenlsher tanks. If you cannot use
floatlng llds, you must flnd another
method of mlnlmlzlng oxldatlon.
2. Ellmlnate, or mlnlmlze, solutlon-to-
alr contact durlng ldle perlods or
perlods of lov utlllzatlon. Use
floatlng llds on rack-and-tank
machlne tanks to cover the solu-
tlons vhenever the machlne ls
up to temperature but ls not
processlng fllm.
}. Routlnely check reclrculatlon
pumps, fllter houslngs, and llnes for
leaks. Make sure that the solutlon
levels are adequate to prevent alr
from enterlng the reclrculatlon
system.
. Follov proper mlxlng procedures.
Do not overmlx solutlons or mlx
them so vlgorously that foamlng or
vortexlng occurs.
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PROCESS MOHTORHG: CHEMCAL AHD MECHAHCAL PARAMETERS 9/91 "
EIiminate er Minimize
Euaperatien
The rate of evaporatlon of a solutlon
depends on the surface-to-volume
ratlo, agltatlon and turbulence, the
temperature of the solutlon, the rela-
tlve humldlty ln the processlng area,
and the rate of alr flov lmmedlately
above the surface of the solutlon.
The sur[ace-te-ueIume ratie ls
the ratlo of the surface area of the
solutlon ln a processlng tank to the
volume of the tank. A lu-gallon tank
that exposes l square foot of solu-
tlon surface has a surface-to-volume
ratlo of l square foot to lu gallons,
or u.l sq ft/gal. A tray vlth a
l-gallon capaclty and a surface area
of l square foot has a ratlo of
l sq ft/gal. The rate of evaporatlon of
the solutlon ln the tray vlll be much
greater than that of the solutlon ln
the tank, because the tray has a
greater surface-to-volume ratlo.
Although a lab may have very llttle
control over the surface-to-volume
ratlo of machlne tanks, lt can control
agitatien and turbuIence. Excesslve
agltatlon or turbulence causes rlpples,
vaves, and bubbles that lncrease the
rate of evaporatlon by lncreaslng the
effectlve surface area of the solutlon.
You can`t ellmlnate all agltatlon and
turbulence because they are essentlal
to process performance. You must
establlsh an acceptable balance
betveen the agltatlon and turbulence
requlred for quallty processlng and
the rate of evaporatlon.
To avold unnecessary evaporatlon,
turn off the agltatlon system of the
flrst developer and the color devel-
oper vhenever you are not
processlng fllm. Use humldlfled
nltrogen for agltatlon ln the flrst
developer and color developer to
mlnlmlze evaporatlon.
The evaporatlon rate also depends
on the temperature of the solutlon.
As temperature lncreases, the rate of
evaporatlon lncreases. Process E-6
requlres a hlgh temperature (luu.
u
F
[}8
u
C]), you cannot lover solutlon
temperatures to reduce evaporatlon.
Hovever, lf you malntaln tlght control
of solutlon temperature, the effect of
temperature on evaporatlon vlll
remaln constant.
The last factors that affect the rate
of evaporatlon are the reIatiue
humidity ln the processlng area and
the rate e[ air [Ieu lmmedlately
above the solutlon. As humldlty
lncreases, evaporatlon decreases.
Malntalnlng a constant level of
humldlty ls lmportant ln avoldlng
fluctuatlons that affect the rate of
evaporatlon. Fluctuatlng rates of
evaporatlon cause fluctuatlons ln
solutlon concentratlons, vhlch may
result ln poor process quallty.
To ellmlnate or mlnlmlze evapo-
ratlon, follov these guldellnes:
l. Avold excesslve agltatlon and
turbulence, turn off agltatlon
systems vhen you are not
processlng fllm.
2. Use humldlfled nltrogen for
agltatlon ln the flrst developer and
color developer.
}. Avold lov or varlable humldlty
ln the processlng area.
. Avold excesslve alr flov or exhaust
over the processlng tanks.
Monltor the concentratlon of your
flrst developer, reversal bath, and
color developer frequently by maklng
speclflc-gravlty measurements and
plottlng your varlatlons from alm on
control charts. If your speclflc-gravlty
measurements are stlll hlgh after you
have folloved the steps descrlbed
earller, and the problem ls not caused
by replenlsher mlxlng errors, compen-
sate for the remalnlng evaporatlon by
follovlng the procedure glven ln
Appendlx A, "Compensatlng for
Evaporatlon.`
Oncc ycu hnuc ccrrcctcd cxidnticn
nnd cunpcrnticn prcbicms, ycu cnn
bcgin tc mcnitcr thc kcy prcccss
pnrnmctcrs.
2/92 PROCESS MOHTORHG: CHEMCAL AHD MECHAHCAL PARAMETERS "!
Process E-6 Solution
Range of Standard
ASTM No.
Hydrometer
First developer and replenisher 1.050 to 1.100 126H
Reversal bath and replenisher 1.000 to 1.050 125H
Color developer an replenisher
Pre-bleach and replenisher
Bleach* and replenisher 1.100 to 1.150 127H
1.150 to 1.200 128H
1.200 to 1.250 129H
1.250 to 1.300 130H
Fixer* and replenisher 1.000 to 1.050 125H
1.050 to 1.100 126H
PROCESS
MONITORING
The follovlng pages descrlbe the key
process parameters, outllne proce-
dures for measurlng the parameters,
explaln hov to plot varlatlons from
alm, and dlrect you to the approprlate
sectlons for lnstructlons on taklng
correctlve actlon.
The key parameters descrlbed are
Speclflc gravlty
Replenlshment rates
Tlme
Temperature
Reclrculatlon
Agltatlon
Concentratlons of key chemlcal
components
Nete. Use measurlng lnstruments
that are sufflclently accurate to
measure and control the key parame-
ters to the speclflcatlons.
5peci[ic Grauity
Speclflc gravlty ls the ratlo of the
mass of a llquld to the mass of an
equal volume of vater at a speclflc
temperature. For example:
Using 5tandard Hydremeters te
Measure 5peci[ic Grauity. A stan-
dard hydrometer ls a tapered alr-fllled
glass tube vlth a stem at the top and
a velght at the bottom. Measure-
ments ln lncrements of u.uul are
marked on the stem. To measure the
speclflc gravlty of Process E-6 solu-
tlons, you vlll need the standard
hydrometers llsted ln the table belov.
Nete. You should nct need all 6 stan-
dard hydrometers llsted ln the table
for any one type of machlne runnlng
Process E-6.
Speclflc gravlty
of Llquld A
~
mass of Llquld A
mass of vater
(equal volume)
at a speclflc
temperature
*More than one hydrometer is listed for bleach and fixer because the acceptable ranges of the
specific-gravity measurements for these solutions are large.
Speclflc-gravlty measurements lndl-
cate the overall concentratlon of
processlng solutlons, and can help
you detect replenlsher mlxlng errors,
lmproper concentrate-to-vater ratlos
ln blender or ln-llne dllutlon systems,
or evaporatlon problems. Measure the
speclflc gravlty of each replenlsher
mlx before uslng the replenlsher.
Speclflc-gravlty measurements dc
nct lndlcate lncorrect replenlshment
rntcs. For Process E-6 solutlons, the
concentratlon of the replenlshers ls
approxlmately equal to the concen-
tratlon of the seasoned tank solu-
tlons. Therefore, under- or over-
replenlshment vlll nct slgnlflcantly
change the speclflc-gravlty measure-
ments, but vlll affect the concen-
tratlons of certaln chemlcal
components.
Make speclflc-gravlty measure-
ments vlth a set of standard hydrom-
eters or the KDAK Process Hydrom-
eter Syphon Set (see page -).
PROCESS MOHTORHG: CHEMCAL AHD MECHAHCAL PARAMETERS 7/04 ""
To use a standard hydrometer, you
must extract tank solutlon and place
lt ln a graduated cyllnder (or slmllar
vessel), and lnsert the hydrometer
lnto the cyllnder.
Equipmcnt Nccdcd
l. Standard hydrometers (see the
table on page -})
2. 2u mL graduated cyllnder or
slmllar vessel
}. Tray
. Thermometer
. Sampllng bulb (battery type or
equlvalent)
Mcnsuring Spccijic Crnuity
l. Flll the dry, clean 2u mL graduated
cyllnder to vlthln l lnch (2. cm) of
the top vlth the solutlon you are
measurlng.
2. Ad|ust the solutlon to the proper
temperature (see the speclflcatlons
glven ln the sectlons on the lndl-
vldual solutlons). Frcpcr sciuticn
tcmpcrnturc is ucry impcrtnnt.
}. Place the cyllnder ln a slnk or tray
to catch overflov.
. Choose the correct hydrometer to
match the approxlmate speclflc
gravlty of the solutlon. (See the
hydrometer ranges llsted ln the
table on page -}.)
. Be sure that the hydrometer ls
clean and dry. Carefully lover the
hydrometer lnto the solutlon.
Let lt bob up and dovn sllghtly.
Vhen lt stops, read the number
at the top of the MENISCUS, see
Flgure l.
6. After maklng the measurement,
dlscard the sample. To avold
contamlnatlng solutlons, de net
return the sample to the tank.
7. Rlnse the hydrometer and gradu-
ated cyllnder thoroughly vlth
vater.
Nete. Never take speclflc-gravlty
readlngs of solutlons ln the tanks. If
you use the vrong hydrometer, lt can
slnk to the bottom of the tank and
break, or bob on the surface, vhere
the stem may hlt the edge of the tank
and break. Label hydrometer boxes to
avold confuslon.
Do not use tape labels on the
hydrometers.
Figure 1
Line of vision
Reading is 1.063
Hydrometer stem
Solution level
MENISCUS
9/91 PROCESS MOHTORHG: CHEMCAL AHD MECHAHCAL PARAMETERS "#
Using the KODAK Frecess
Hydremeter 5yphen 5et te
Measure 5peci[ic Grauity. The
KDAK Process Hydrometer Syphon
Set conslsts of a glass tube vlth a
three-hole plug and a rubber suctlon
bulb lnstalled on the upper end, a
hydrometer that flts lnslde the glass
tube, and a three-hole plug and a
rubber nozzle vlth a clamp for the
lover end of the glass tube. Use thls
hydrometer set to extract solutlons
dlrectly from your processlng tanks to
measure the speclflc gravlty of the
solutlons at luu.
u
F (}8
u
C).
Asscmbiing thc Syphcn Sct
l. Insert the HYDRMETERstem
[irstlnto the CLASS TUBE through
the lover end, see Flgure 2.
2. Insert the three-hole plug lnto the
lover end of the glass tube.
}. Vet the rubber NZZLE and the
bottom of the glass tube vlth tap
vater, and flt the nozzle over the
end of the tube. Handle the nozzle
carefully, lt contalns a glass |olnt.
Mcnsuring Spccijic Crnuity
l. Before you make the flrst measure-
ment, open the CLAMP and drav
varm vater lnto the tube by
squeezlng the SUCTIN BULB and
releaslng lt. Then squeeze the bulb
agaln to expel the vater.
Nete. De net use cold vater, the
hydrometer could crack vhen you
later drav varm solutlon lnto the
tube.
2. Squeeze the suctlon bulb be[ere
lmmerslng the nozzle lnto the tank
solutlon.
}. Immerse the nozzle lnto the solu-
tlon at least l lnch (2. cm) belov
the surface. To drav the solutlon
lnto the glass tube, gradually
release your grlp on the suctlon
bulb.
Impertant. Perform thls operatlon
slovly to avold dravlng alr lnto the
tube and to prevent solutlon
foamlng, vhlch can affect your
readlng. Your measurements may
be hlgh lf you drav alr lnto the
tube.
As soon as the bottom of the
hydrometer stem reaches the
narrov sectlon of the glass tube
(see Flgure 2), close the clamp on
the nozzle so that the solutlon
remalns ln the tube. Release your
grlp on the suctlon bulb. The
amount of solutlon that you drav
lnto the tube vlll depend on the
speclflc gravlty of the solutlon, so
the solutlon level ln the tube vlll be
dlfferent for dlfferent solutlons.
. Hold the syphon set vertlcally.
Cently shake or tap the glass tube
to make sure that the hydrometer
floats freely and to dlslodge alr
bubbles. The hydrometer should
not touch the sldes of the tube.
Nete. If you cannot dlslodge alr
bubbles from the hydrometer,
dlscard the sample and drav
another one.
Figure 2
Line of vision
Reading is 1.035
Hydrometer stem
Solution level
MENISCUS
SUCTION BULB
Correct
hydrometer
position
HYDROMETER
GLASS TUBE
NOZZLE
CLAMP
KODAK Q-LAB Process Monitoring Service
PROCESS CONTROL HANDBOOK Z-6

PROCESS MONITORING: CHEMICAL AND MECHANICAL PARAMETERS 7/04 4-6
5. To make the measurement, hold
the set so that the solution is at
eye level. Read the number on the
hydrometer at the top of the
MENISCUS; see the enlarged
portion of Figure 2.
6. To discard the sample from the
tube, open the clamp and squeeze
the bulb to expel the solution. To
avoid contaminating solutions, do
not return the sample to the tank.
7. Rinse the set thoroughly by
drawing warm water into the tube
and expelling it. Do this 3 times.
To avoid breaking the glass tube
and the hydrometer, store the set in
its original box or another safe place.
Note: A crossover procedure for
hydrometers is given in Appendix
4B.

Plotting Specific-Gravity
Measurements: After you
measure the concentration of your
tank solutions, calculate and plot
your variations from aim on the
appropriate plotting form; see
Using Forms Y-34, Y-35, and
Y-36 on page 4-13 for more
information. Check the plots of
specific-gravity measurements for
outliers, shifts, trends, and cycling to
determine the state of control. If you
detect an out-of-control condition,
refer to the diagnostic charts in the
sections on the individual solutions.

Replenishment Rates
The correct chemical composition of
tank solutions is critical to optimum
performance of Process E-6. For
optimum quality in the many films
for Process E-6, the chemical
composition of tank solutions must
be on aim and remain stable.
Many chemical reactions occur
during processing. These reactions
affect the concentration of key
chemical components in the tank
solutions. When you replenish
Process E-6 solutions properly, you
maintain optimum levels of
chemicals in the process.
Replenishers for Process E-6 contain
a higher concentration of the
chemicals that are consumed or
oxidized during processing than a
seasoned tank solution. The higher
concentration of these chemicals in
replenisher solutions restores the
proper chemical concentration of
tank solutions. Replenisher solutions
also dilute some developer by-
products (e.g., bromide and iodide)
and other reaction by-products.
When properly operated and
monitored, replenishment systems
will maintain the chemical
composition of tank solutions at
their optimum (aim) level.
Note: Replenishment rates for
Process E-6 are based on average film
exposure and a typical mix of low- and
high-speed films. If you process a non-
typical film mix (e.g., all low-speed films)
or films with unusual exposure levels
(e.g., a majority of high- or low-key
scenes per roll or batch), you may have to
adjust your replenishment rates or
replenisher concentration (or both) to
maintain proper tank concentrations.
The composition of the tank solution is
critical; you must carefully monitor
replenishment rates, as well as replenisher
concentration, to maintain the
composition of the tank solution.

Calculating Replenishment
Rates:
To calculate the replenishment rate
for each solution, you must
determine the amount of replenisher
used and the amount of film
processed. For pre-mixed solutions,
you can use the formula:

amount of
replenisher used (mL) Replenish-
ment rate = amount of
film processed (sq ft)

For in-line dilution and blender
systems, you can use a similar
formula, but you base the calculation
on each flexible container of
concentrate (see page 4-8).

For Pre-Mixed Solutions: We
recommend that you calculate and
plot replenishment-rate data as often
as possibleat least once a week.
Calculate replenishment rates by
following these steps or by using
Worksheet 1.
(A sample replenishment-rate
calculation on Worksheet 1 is shown
on page 4-7. A copy of Worksheet 1
is included in Section 17.)
1. Record the volumeof replenisher
in the replenisher tank at the
beginning of the day or shift.
Note: Throughout the day or
shift, record the amount of film
processed (in square feet). The
table on Worksheet 1 lists
equivalents in square feet for
different film formats.
2. At the end of the shift, record the
volume of replenisher in the
replenisher tank.
3. Determine the amount of
replenisher used by subtracting
the volume you recorded in step 2
from the volume you recorded in
step 1.
4. Record the volume used for pump
calibrations and waste.
5. Subtract the amount of
replenisher used for pump
calibrations (waste) from the
volume you calculated in step 3 to
determine the amount of
replenisher used to process film.
6. Calculate the amount of film
processed (in square feet). If you
push process film, see note on
Worksheet 1 example.
7. Divide the amount of replenisher
used (step 5) by the amount of
film processed (step 6) to
determine the replenishment rate.
Round the result, if necessary.

Example:

Replenishment rate =
19,000 mL
=
203.47 mL/sq ft,
rounded to
93.38 sq ft
203 mL/sq ft mL)

8. Calculate and plot your variation
from aim on the appropriate
plotting form; see Using Forms
Y-34, Y-35, and Y-36 on page
4-13 for more information. Check
the plots of replenishment rates
for outliers, shifts, trends, and
cycling to determine the state of
control. If you detect an out-of-
control condition, refer to the
diagnostic charts in the sections
on the individual solutions.

7/04 PROCESS MONITORING: CHEMICAL AND MECHANICAL PARAMETERS

4-7


WORKSHEET 1 EXAMPLE

CALCULATION OF REPLENISHMENT RATES
FOR PRE-MIXED SOLUTIONS

To calculate the replenishment rate of each solution, determine the amount of replenisher used and
the amount of film processed. Use the formula:

Replenishment rate = amount of replenisher used (mL)
amount of film processed (sq ft)

1. Volume of replenisher at start-up: 46,000 mL
2. Volume of replenisher at shutdown:
26,000
mL
3. Volume of replenisher used (1 2):
20,000 mL
4. Volume used for pump calibrations/waste:
1,000 mL
5. Volume of replenisher used to process film (3 4):
19,000 mL
6. Total film processed*:
93.38 mL
7. Replenishment rate (5 6):
203.47 or mL/sq ft

203 mL/sq ft

* If you push process film, the film area for pushed film must be increased by the same percentage as the increase in replenisher rate.
Example: If 1.1 square feet of film is processed at push one and the push one replenishment rate is 1.5x normal, the 1.1 sq ft of film
should be accounted for as 1.65 sq ft (1.5 x 1.1=1.65)

Example:

Replenishment rate = 19,000 mL = 203.47 mL/sq ft
93.38 sq ft (rounded to 203 mL/sq ft)

STANDARD REPLENISHMENT RATES
Solution
STANDARD
REPLENISHMENT RATES
(mL/sq ft)
First developer 200
Reversal bath 100
Color developer 200
Pre-bleach 100
Bleach Depends on machine type
Fixer 100
Final rinse 100

EQUIVALENTS IN SQUARE FEET
FOR FILM FORMATS
Film Size
Area Per
Sheet or Roll
(Square Feet))
4 x 5-in sheets 0.134
11 x 14-in sheets 1.064
135-24 0.395
135-36 0.556
120 0.550
220 1.090


PROCESS MONITORING: CHEMICAL AND MECHANICAL PARAMETERS 7/04
4-8
For In-Line Dilution and Blender
Systems: We recommend that you
base replenishment-rate
calculations on each flexible
container of concentrate used. (It
is difficult to measure use of
partial amounts of concentrate
from a flexible container, so the
rates are calculated from the total
volume of the flexible container.)
You must keep a careful record
of all pump calibrations and any
concentrate that is wasted (i.e.,
concentrate that is not added to
the tank). Calculate
replenishment rates by following
these steps or by using
Worksheet 2. (A sample
replenishment-rate calculation on
Worksheet 2 is shown on
page 4-9. A copy of Worksheet 2
is included in Section 17.)
1. When you install a new flexible
container, begin recording the
amount of film you process (in
square feet). The table on Work-
sheet 2 lists equivalents in square
feet for different film formats.
2. Keep a record of the
concentrate that you remove
from the flexible container for all
pump calibrations/waste.
3. When the flexible container is
empty, determine the amount of
concentrate removed for pump
calibrations/waste by totaling the
amounts recorded in step 2.
4. Subtract the total amount of
concentrate used for pump
calibrations/waste from the
original volume of concentrate in
the flexible container (the
volume marked on the flexible-
container carton) to calculate the
amount of concentrate used.
5. Calculate the amount of film
processed (in square feet).
6. Divide the amount of
concentrate used (step 4) by
the amount of film processed
(step 5). Round your result, if
necessary
Example:

7. To determine the replenishment
rate, add the amount of water
used per square foot of film (use
the amount from the table
below) to the amount of
concentrate used per square foot
of film.

Example:

8. Calculate and plot your
variation from aim on the
appropriate plotting form;
see Using Forms Y-34,
Y-35, and Y-36 on page
4-13 for more information.
Check the plots of
replenishment rates for
outliers, shifts, trends, and
cycling to determine the
state of control. If you
detect an out-of-control
condition, refer to the
diagnostic charts in the
sections on the individual
solutions.

Amount of
Concentrate Used 18,670 mL 40.49 mL/sq ft,
= = rounded to
Amount of 461 sq ft 40 mL/sq ft
Film Processed*

* If you push process film, the film area for pushed film must be increased by the same
percentage as the increase in replenisher rate. Example: If 1.1 square feet of film is
processed at push one and the push one replenishment rate is 1.5x normal, the 1.1 sq ft
of film should be accounted for as 1.65 sq ft (1.5 x 1.1=1.65)
Replenisher
Solution
Volume of
Water Used*
per Square
Foot of Film
Processed
(mL/sq ft)
First developer
Reversal bath
Color developer
Pre-bleach
Bleach
Fixer
Final rinse
160
95
120
90
0
90
99
*Based on pump calibrations that indicate
the proper ratio of water to concentrate. If
you are compensating for evaporation, use
the modified value for your water pump.

40 mL/sq ft 160 mL/sq ft
of concentrate + of water = 200 mL/sq ft

9/91 PROCESS MOHTORHG: CHEMCAL AHD MECHAHCAL PARAMETERS "'
WORKSHEET 2
CALCULATION OF REPLENISHMENT RATES FOR
IN-LINE DILUTION/BLENDER SYSTEMS
Calculate replenishment rates based on the total volume of each flexible container of concentrate used. Keep
a careful record of pump calibrations and any concentrate that is wasted (i.e., concentrate that is not added to
the tank).
Solution: ____________________ Batch No.: ____________________
3. Total the amounts of concentrate recorded in step 2.
4. Subtract the total amount of concentrate used for pump calibrations/
waste (step 3) from the original volume of concentrate in the container.
5. Total the amounts of film recorded in step 1.
6. Divide the amount of concentrate used to process film (step 4) by
the amount of film processed (step 5).
7. To determine the replenishment rate, add the amount of water used
per square foot of film (use the amount from the table on the reverse
side) to the amount of concentrate used (step 6).
1. Record the amount of film processed daily.
2. Record the amount of concentrate removed from the container for daily pump calibrations/waste.
Date
Film
Processed
(sq ft)
Amount of
Concentrate
Used for Pump
Calibrations/
Waste (mL) Comments
____________________ mL
____________________ mL/sq ft
____________________ sq ft
19,000 ____________________ mL = ____________________ mL
____________________ mL/sq ft ____________________ mL/sq ft = ____________________ mL/sq ft
Q
R
EXAMPLE
!'4 !'4 !'4 !'4 !'4 9 9 9 9 9 c2 c2 c2 c2 c2
!' !' !' !' !' 4 4 4 4 4 c c c c c
!'C !'C !'C !'C !'C C' C' C' C' C' c' c' c' c' c'
!'7 !'7 !'7 !'7 !'7 C C C C C 7c 7c 7c 7c 7c
!' !' !' !' !' 4 4 4 4 4 7 7 7 7 7
!29 !29 !29 !29 !29 C C C C C c9 c9 c9 c9 c9
!2' !2' !2' !2' !2' C9 C9 C9 C9 C9 74 74 74 74 74
!22 !22 !22 !22 !22 C9 C9 C9 C9 C9 c c c c c
Cc Cc Cc Cc Cc
Cc Cc Cc Cc Cc 'c,C2 'c,C2 'c,C2 'c,C2 'c,C2
449 449 449 449 449
4'.7 4'.7 4'.7 4'.7 4'.7
4'.7 4'.7 4'.7 4'.7 4'.7 'C9 'C9 'C9 'C9 'C9 29'.7 29'.7 29'.7 29'.7 29'.7 ot
292 292 292 292 292 mL7sg /1
Zo]us1eo pump
Zo]us1eo pump
no o/ con1cInet
FIts1 Dev
Time
Reactlons ln the flrst developer are
the most sensltlve to tlme varlatlons.
Changes ln the flrst-developer tlme
have slgnlflcant photographlc effects,
e.g., a change of only } seconds can
result ln a denslty dlfference of about
u.ul at a denslty of l.uu. Reactlons ln
the other solutlons go to completlon,
they are less sensltlve to tlme varl-
atlons, partlcularly longer tlmes.
Impertant. \cu must mcnsurc thc
jirst-dcucicpcr timc daiIy. Measure
the tlmes of all other solutlons once
a month.
Use a stopvatch to measure the
tlme that the fllm ls ln a solutlon from
the tlme the fllm enters the solutlon
to the tlme lt enters the next solutlon
(or vash).
Nete. The optlmum tlme for a solu-
tlon vlll vary from processor to
processor due to dlfferences ln
machlne deslgn, agltatlon, tempera-
ture, and crossover tlmes. nce you
determlne the optlmum tlme for each
solutlon ln a machlne, you should
malntaln these tlmes to } seconds.
Calculate and plot your varlatlon
from alm on the approprlate form,
see "Uslng Forms Y-}, Y-}, and
Y-}6` on page -l} for more lnforma-
tlon. Check the plots for outllers,
shlfts, trends, and cycllng to deter-
mlne the state of control. If you detect
an out-of-control condltlon, refer to
the dlagnostlc charts ln the sectlons
on the lndlvldual solutlons.
Temperature
The temperature of a solutlon
controls the rntc of the chemlcal reac-
tlons. Make sure that your reclrcu-
latlon system ls functlonlng properly.
The most crltlcal temperature ln
Process E-6 ls the flrst-developer
temperature. A temperature change
of u.2
u
F ( u.l
u
C) can result ln a
denslty dlfference of about u.ul at a
denslty of l.uu.
Impertant. You must control the
flrst-developer temperature to vlthln
u.2
u
F ( u.l
u
C) to control denslty
vlthln u.ul.
The temperature of the color devel-
oper ls also lmportant. A temperature
change of u.
u
F ( u.}
u
C) ln the
color developer can result ln color
and denslty shlfts. Control the
temperature of the color developer to
vlthln u.
u
F ( u.}
u
C) for optlmum
process performance.
You must malntaln the temperature
of a solutlon unijcrmiy throughout
the process tank, the temperature of a
solutlon must nct fluctuate vhen you
add replenlsher. (If the tank tempera-
ture decreases durlng replenlshment,
you should preheat your replenlsher
solutlon.)
Properly deslgned and malntalned
reclrculatlon systems help you maln-
taln a unlform tank temperature. To
check that your reclrculatlon system
ls vorklng properly and that lt ls
keeplng the tank temperature
unlform, perlodlcally measure the
temperature of the solutlons at
dlfferent locatlons ln the process
tanks.
Impertant. Vhen you monltor and
plot the temperature of the flrst devel-
oper and color developer, make sure
that you make the measurement at
the same locatlon ln each tank for
conslstency.
Measure the temperature of the
developers daiIy. Calculate and plot
your varlatlon from alm on the appro-
prlate plottlng form, see "Uslng Forms
Y-}, Y-}, and Y-}6` on page -l} for
more lnformatlon. Check the plots for
outllers, shlfts, trends, and cycllng to
determlne the state of control. If you
detect an out-of-control condltlon,
refer to the dlagnostlc charts ln the
sectlons on the lndlvldual solutlons.
RecircuIatien
Proper reclrculatlon ls lmportant to
malntaln a unlform tank temperature
and to provlde unlform chemlcal
dlstrlbutlon. Poor reclrculatlon can
cause temperature varlatlons ln a
tank that result ln nonunlform devel-
opment or lnconslstent development
vlthln a rack or across a tank.
Reclrculatlon and agltatlon do not
provlde the same functlon. Agltatlon
helps remove the by-products of
chemlcal reactlons so that fresh
chemlcals can act on the fllm. Poor
reclrculatlon can cause poor aglta-
tlon, but good reclrculatlon does not
guarantee good agltatlon.
Inspect the reclrculatlon systems of
the flrst-developer, color-developer,
bleach, and flxer tanks dally. Keep a
record of all checks on the systems.
Note any changes and take correctlve
actlon, lf necessary.
Agitatien
Agltatlon helps remove the by-
products of the chemlcal reactlons
so that fresh chemlcals can act on
the fllm. Proper agltatlon ls crltlcal for
process control and unlformlty of the
flnal lmages, lt ls especlally lmportant
ln the flrst developer, flrst vash, and
color developer. Poor or lnsufflclent
agltatlon may result ln nonunlformlty
and streaklng.
Dlfferent types of machlnes use
dlfferent methods of agltatlon. In
roller-transport processors, the rollers
provlde the agltatlon, you cannot
ad|ust the agltatlon of these
processors.
The bleach requlres aeratlon to
malntaln actlvlty. If the actlon of the
rollers does not provlde enough
aeratlon ln the bleach tank, you may
also have to use alr agltatlon.
2/92 PROCESS MOHTORHG: CHEMCAL AHD MECHAHCAL PARAMETERS "
In rack-and-tank machlnes, nltrogen
and alr provlde the agltatlon. To
mlnlmlze evaporatlon, use humldlfled
nltrogen for agltatlon ln the flrst
developer and color developer. Aglta-
tlon should begln as you lover the
fllm lnto the tank. Any delay ln the
lnltlal burstpartlcularly ln the color
developercan result ln streaklng.
The tlmlng of the bursts of nltrogen
and alr ls very lmportant to prevent
streaklng (especlally vhen you
process sheet fllm). A burst should
begln every lu seconds and last for
2 seconds (a cycle conslsts of a
2-second burst folloved by an
8-second rest). Agltatlon must be the
same at the bottom and the top of the
tank. Be sure that the burst pattern ls
even across the tank, vlth flne
bubbles (pea-slzed or smaller), and
that lt ls vlgorous enough to ralse the
solutlon level
/
8
lnch (l6 mm).
Nete. Agltatlon ln some solutlons
may cause foamlng. If foamlng ls
excesslve, determlne the causes of lt
and correct them. Hlgh agltatlon,
loose connectlons on reclrculatlon
pumps, and lov solutlon levels that
permlt alr to be sucked lnto the solu-
tlon can cause excesslve foam.
You can use KDAK Defoamer,
Process E-6, to control foamlng ln the
flrst-developer, color-developer, and
bleach tanks, de net use defoamer ln
the flnal-rlnse tank (lt can leave olly
deposlts on the fllm). Apply a thln
layer of defoamer to the lnslde of the
process tank above the solutlon
levelde net add defoamer dlrectly
to the tank solutlon.
For mcst contlnuous processors,
turbulator bars provlde agltatlon.
Turbulator bars are spray bars that
force fresh chemlcals onto the fllm.
You can check the operatlon of
turbulator bars by lnstalllng pressure
gauges on lncomlng chemlcal llnes.
Vhen the small holes ln the turbu-
lator bars begln to plug, the pressure
vlll lncrease. Vhen you detect a
-pound lncrease ln pressure, clean
the turbulator bars.
Vlsually lnspect the agltatlon ln the
flrst-developer, color-developer, bleach,
flxer, and vash tanks daiIy. Keep a
record of all checks on the agltatlon
system. Plot measurable data (e.g.,
tlmlng of burst, length of burst, solu-
tlon rlse, etc), note any changes, and
take correctlve actlon, lf necessary
Cencentratiens e[ Key
ChemicaI Cempenents
The procedures that have been avall-
able to professlonal labs for monl-
torlng the chemlcal composltlon of
solutlons are speclflc-gravlty
measurements, replenlshment-rate
calculatlons, and replenlsher-pump
callbratlons. These procedures
provlde only lndlrect measurements
of overall solutlon concentratlon or
speclflc chemlcal concentratlons, and
do not enable labs to measure lndl-
vldual chemlcal parameters. Nov, the
KDAK Q-LAB Chemlcal Test Klt,
Process E-6, provldes an easy method
of measurlng the bromlde concen-
tratlon ln the flrst developer, the
reversal-agent concentratlon ln the
reversal bath, and the sulflte concen-
tratlon ln the color developer. These
parameters are lmportant lndlcators
of correct process operatlon. The
Q-LAB Chemlcal Test Klt ls composed
of } klts: KDAK Bromlde Test Klt,
Process E-6, KDAK Reversal Agent
Test Klt, Process E-6, and KDAK
Sulflte Test Klt, Process E-6.
Bremide Cencentratien. Use the
Bromlde Test Klt to detect changes ln
the concentratlon of bromlde ln the
flrst developer bcjcrc they affect the
fllm you process. For example, as
bromlde concentratlon lncreases,
developer actlvlty decreases, and fllm
densltles lncrease. As bromlde
concentratlon decreases, developer
actlvlty lncreases, and fllm densltles
decrease. Bromlde concentratlon ls
affected prlmarlly by replenlshment
rate. Instructlons for uslng thls klt
and dlagnostlcs are glven ln First
Dcucicpcr, Sectlon 7.
ReuersaI-Agent Cencentratien.
Use the Reversal Agent Test Klt to
detect changes ln the concentratlon
of reversal agent ln the reversal bath
bcjcrc they affect the fllm you
process. For example, vhen the
reversal-agent concentratlon ls hlgh,
the process vlll drlft blue, vhen the
concentratlon ls lov, the process vlll
drlft yellov. Vhen the reversal-agent
concentratlon ls cxtrcmciy icu, the
color balance of upper-scale densltles
and D-max vlll drlft green. Instruc-
tlons for uslng thls klt and dlagnostlcs
are glven ln Rcucrsni 8nth, Sectlon 9.
5uI[ite Cencentratien. Use the
Sulflte Test Klt to detect changes ln
the concentratlon of sulflte ln the
color developer bcjcrc they affect the
fllm you process. For example, as
sulflte concentratlon lncreases, fllm
contrast vlll be lover, especlally ln
the hlgh densltles. As sulflte concen-
tratlon decreases, fllm contrast vlll be
hlgher, especlally ln hlgh-denslty
areas. Instructlons for uslng thls klt
and dlagnostlcs are glven ln Ccicr
Dcucicpcr, Sectlon lu.
FREQUENCY OF
MEASUREMENTS
The frequency of measurlng the
process parameters depends on the
state of control of your process. As
you begln process monltorlng, for
example, you must measure the
parameters frequentlymore fre-
quently than typlcal process fluctua-
tlons occur. After your process ls
ln control and ad|usted to alm, you
can measure the parameters less
frequently
When yeu begin precess meni-
tering, ve recommend that you
make at least l measurement of all
key parameters euery 8-heur day
er shi[t. For machlnes that operate
more than l2 hours a day, ve recom-
mend that you measure all key
parameters every 8 to lu hours. The
more measurements you make, the
more data you vlll have to help you
make process-control declslons.
See "Stablllzlng Your Process` ln
Sectlon 6.
A[ter yeur precess has
stabiIized and yeu haue adjusted
it te aim, you can decrease the
frequency of measurement accordlng
to the state of control of your process
and the number of tank solutlon turn-
overs (processor utlllzatlon). Hov-
ever, lf the varlablllty of your data
lncreases (or plots approach the toler-
ance llmlts), you should make mea-
surements more frequentlyat least
once a day. Thls vlll help you detect
out-of-control condltlons qulckly. If
the varlablllty of your data ls small
and your plots are vell vlthln the
tolerance llmlts, you can reduce the
frequency of measurements.
Vhen your process ls ln control
on alm vlth mlnlmum varlablllty
base your frequency of measure-
ments on the number and frequency
of tank turnovers for the flrst devel-
oper. A tank turnover ls the polnt at
vhlch the volume of replenlsher used
ls equal to the orlglnal volume of
solutlon ln the process tank at
start-up. To determlne the number
of tank turnovers, use the formula:
After you determlne the number of
flrst-developer tank turnovers per
veek, determlne the frequency of
measurements from the follovlng
table.
If your processor has fever than
' turnover per veek, lts utlllzatlon ls
relatlvely lov. Measure the key
parameters at least euery day to
ensure that oxldatlon and evapo-
ratlon do not adversely affect process
control, and that your replenlsher
concentratlon and replenlshment rate
are sufflclent to malntaln proper solu-
tlon concentratlons.
ne-half to 2 turnovers per veek ls
consldered average utlllzatlon. After
your process ls stable, you can reduce
the frequency of measurements to
once every } days. Thls rate ls
adequate to detect problems caused
by oxldatlon, evaporatlon, and
lmproper replenlshment.
If your processor has more than
2 turnovers per veek, lts utlllzatlon
ls relatlvely hlgh. Measure the key
parameters at least euery day to
ensure that you detect changes
before they affect the fllm you
process. Vlth hlgh utlllzatlon, you run
a hlgh rlsk of not detectlng problems
soon enough unless you measure the
parameters at least once a day Ve
recommend that you measure the
parameters more frequently than
once a day.
Nete. It ls lmportant to make
measurements more frequently than
typical when process fluctuations
occur. The frequencies recommended earller
are startlng polnts. Base measurement
frequency on the performance record
of each machlne.
volume of
flrst developer
replenlsher
used
volume of the
flrst-developer
tank
per veek ~
Number
of tank
turnovers
ExampIe.
8u L
luu L
u.8 turnovers
per veek
~
Number
of tank
turnovers
~
First-Developer
Tank Turnovers
Per Week
Minimum
Frequency of
Measurements*
Fewer than '
' to 2
More than 2
Once per day
Once every 3 days
Once per day
*After your process is stable and in control.

7/04 PROCESS MONITORING: CHEMICAL AND MECHANICAL PARAMETERS
4-13
PLOTTING
CHEMICAL
AND MECHANICAL
PARAMETERS
KODAK Publications No. Y-34,
Y-35, and Y-36 provide a
convenient means of tracking the
key process parameters. Use
Form Y-34, KODAK First
Developer Plotting Form for
Process E-6, to track tank
temperature, specific gravit, time,
replenishment rate, and bromide
concentration for your first
developer. Use Form
Y-35, KODAK Reversal Bath
Plotting Form for Process E-6, to
track specific gravity,
replenishment rate, and reversal-
agent concentration for your
reversal bath. Use Form Y-36,
KODAK Color Developer
Plotting Form for Process E-6, to
track tank temperature, specific
gravity, replenishment rate, and
sulfite concentration for your
color developer.
These forms include color
zones that enable you to
determine the control status of
your process quickly and easily.
The following colors are used:
Whiteindicates that your
process is in excellent control in
relation to professional standards
Yellowindicates that your
process is in marginal control in
Orangeindicates that your
process is out of control in

Aims for Chemical and
Mechanical Parameters
We recommend that you control
your process to the aims
provided in the sections on the
individual solutions. However,
we recognize that professional
labs may have to adjust the aims
of some parameters to obtain
optimum image quality; the
sections on the individual
solutions give an acceptable range

for these parameters. (For more
information on acceptable
ranges, see Process Specifications,
Section 2.)
After you make chemical and
mechanical measurements for
your first developer , reversal
bath, and color developer , plot
the variations from aim on
Forms Y-34, Y -35, and
Y-36.

Using Forms Y-34, Y-35,
and Y-36
Use a separate set of forms for
each processor .
1. Record the name (or identity
code) of the processor in the
blank labeled Machine. On
each form.
2. Record the aim value for each
parameter in the appropriate
blank on each form.
3. Make the required chemical
and mechanical measurements.

To calculate and plot your
variations from aim, follow these
steps:
1. Subtract the aim values from
the measurements to calculate
the differences.
Example of determining the
difference between a
measurement and your aim
value:

First-developer
temperature 100.6F
Aim value 100.4F
Difference + 0.2F

2. Plot the differences on the
appropriate form for each
parameter . Plot differences that
are larger than the
corresponding aim values
(+ values) above the aim line, and
those that are smaller than the
aim values ( values) below the
line. If all of your data plots
within the scales on Forms
Y-34, Y-35, and Y-36, proceed to
Stabilizing Your Process in
Section 6.

If the difference from aim for any
parameter exceeds the scale on
the form when you begin process
monitoring, take another
measurement.

Example:

Color-developer
temperature(first
measurement) 99.2F
Aim value 100.4F
Difference - 1.2F*

*Difference exceeds the scale of Form
Y-36; in this case you would take another
measurement.

If your second measurement
matches your first measurement
closely , calculate the average of
the 2 measurements, and use this
value as a temporary aim. In the
example above, the second
measurement was 99.4 0 F, so the
operator calculated the temporary
aim as 99.3 0 F.
Unless you can determine and
fix the causes of an out- of-
control condition, do not make
any adjustments to your process
at this point.
If your second measurement is
closer to aim (e.g., the difference
from aim does not exceed the
scale on the plotting form), plot
the difference from aim and then
proceed to Stabilizing Your
Process in Section 6.

PROCESS MONITORING: CHEMICAL AND MECHANICAL PARAMETERS 7/04
4-14
SAFE HANDLING
OF PHOTOGRAPHIC
CHEMICALS
Handle photographic chemicals
and processing solutions with
care. See Safe Handling of
Photographic Chemicals, KODAK
Publication No. J-98A. For more
information about potential
health hazards and safe handling
of specific Kodak chemicals, see
the package label and the
Material Safety Data Sheet
(MSDS) for the chemicals.
Packages of Kodak photographic
chemicals have precautionary
labels when necessary. Always
read the labels and follow the
instructions carefully. Also read
the Material Safety Data Sheets
(MSDSs) for the chemicals for
precautionary information.*
Keep the darkroom, processing
area, and mixing room clean.
Clean up spilled chemicals
promptly.
Use personal protective
equipment, such as a waterproof
apron and impervious gloves
made of a material such as
Neoprene or nitrile, when you
handle solutions. Always wear
goggles or safety glasses when
you mix solutions from
concentrates.

* In the USA, you can obtain MSDSs
for Kodak via the internet. You can
download them from the Kodak web
site: www.kodak.com/go/MSDS.
Outside of the USA, contact Kodak
in your country. Please supply the
catalog (CAT) numbers for the
chemicals when you request MSDSs.
Avoid contact of any chemicals with
your skin; some photographic solutions,
particularly developers, can cause
skin irritation and an allergic skin
reaction. In case of accidental
chemical contact, wash your skin
with running tap water and a non-
alkaline (slightly acid) hand cleaner.
If symptoms persist, get medical
attention.
Keep chemical solutions out of your
mouth. Never start a siphoning
action with your mouth. Do not eat
or drink in a room where chemicals
are mixed or used.
Maintain proper ventilation in the
mixing room and processing area.
Store chemicals and processing
solutions safely. Keep them out of
the reach of children.
Dispose of solutions safely. See
Dealing with Hazardous Waste and
Processing Effluents at Photographic
Processing Facilities, KODAK
Publication No. J-411.

9/91 PROCESS MOHTORHG: CHEMCAL AHD MECHAHCAL PARAMETERS "#
COMPENSATING FOR
EVAPORATION
Vhen vater evaporates from
processlng solutlons, the chemlcal
components remaln, and the solutlon
becomes overconcentrated. After you
have folloved the steps to mlnlmlze
the causes of evaporatlon (see
page -2), hlgh speclflc-gravlty
measurements may lndlcate that
evaporatlon ls stlll occurrlng. To
compensate for any remalnlng
evaporatlon that occurs durlng oper-
atlng hours, follov the procedure
glven belov. The procedure helps you
to determlne hov much vater ls lost
durlng dally operatlon and hov to
ad|ust your replenlsher and replen-
lshment rate to compensate. It
requlres you to make speclflc-gravlty
measurements at start-up and shut-
dovn to determlne the amount of
vater lost to evaporatlon, lt does
not lnterfere vlth your normal
operatlons.
Nete. nce you have compensated
for evaporatlon that occurs durlng
operatlng hours, you can easlly
compensate for overnlght evap-
oratlon by addlng vater to "top off `
your tank solutlons.
Calculate the average amount of
fllm (square feet or square metres)
that you process per day. Then follov
these steps to compensate for evap-
oratlon that occurs durlng operatlng
hours.
APPENDIX 4A
5tep Why? ExampIe
6. Multlply the change ln solutlon
concentratlon (step ) by the
volume of your tank.
. Dlvlde the change ln speclflc
gravlty from step } by the chem-
lcal component of the solutlon
speclflc gravlty from step .
. Subtract the speclflc gravlty of
vater (l.uuu) from the start-up
speclflc gravlty (step l).
}. Subtract the start-up speclflc
gravlty from the shutdovn
speclflc gravlty.
2. Measure the speclflc gravlty of
your tank solutlon at shutdovn.
l. Measure the speclflc gravlty of
your tank solutlon at start-up.
Then operate your machlne as
you normally do.
l. Establlshes the concentratlon
of the solutlon at the start of
the day.
l. l.u6}
6. Determlnes the total amount of
vater lost due to evaporatlon.
. Determlnes the percent change
ln solutlon concentratlon.
. Determlnes the chemlcal
component of the solutlon
speclflc gravlty.
}. Determlnes the change ln solu-
tlon concentratlon.
2. Establlshes the concentratlon
of the solutlon at the end of
the day.
6. u.u}2 x luu L ~ }.2 L or }2uu mL
. u.uu2 u.u6} ~ u.u}2 (or }.2 percent)
. l.u6} l.uuu ~ u.u6}
}. l.u6 l.u6} ~ u.uu2
2. l.u6
(Ccntinucd cn ncxt pngc)
PROCESS MOHTORHG: CHEMCAL AHD MECHAHCAL PARAMETERS 7/04 "$
5tep Why? ExampIe
7. Dlvlde the amount of vater lost
to evaporatlon (step 6) by the
average amount of fllm
processed to calculate the vater
addltlon.
7. Determlnes the vater loss ln the
same unlts as your replenishment
rate (e.g., mL/ft
2
or mL/m
2
).
7. }2uu mL luu ft
2
~ 29 mL/ft
2
(}2uu mL lu.2 m
2
~ }l mL/m
2
)
Increase your total replenishment
rate by the addltlonal volume of
vater per square foot or square
metre.
Then multlply the amount of fllm
by the vater addltlon from Step 7.
Fer pre-mixed seIutiens, flrst
dlvlde the volume of replenisher
you mlx by your alm replen-
lshment rate.
Your tctni replenlshment rate vlll
lncr ease by the addltlonal volume
of vater per square foot (or
square metre).
Fer in-Iine diIutien/bIender
systems, lncr ease the output of
the vater pump by the vater
addltlon from step 7.
8. Ad|ust the amount of vater ln
the r eplenlsher by uslng the
vater addltlon you calculated ln
step 7.
Nete. The vater addltlon ls
based on each squar e foot (or
squar e metr e) of fllm pr ocessed
because you r eplenlsh the solu-
tlon for each squar e foot (or
squar e metr e) of fllm you
process.
Provldes the same amount of
chemlcal components (per
replenlshment cycle) that your
system provided befor e you
ad|usted the replenlsher to
compensate for evaporatlon.
Determlnes hov much e xtra
vater to add to each replenlsher
mlx.
Determlnes the amount of fllm
you can process vlth that
volume of replenisher .
8. Compensates for the evaporatlon
that occurs durlng operatlng
hours.
200 mL/ft
2
29 mL/ft
2
~ 229 mL/ft
2
(2l} mL/m
2
}l mL/m
2
~ 267 mL/m
2
)
7 ft
2
x 29 mL/ft
2
~ l},77 mL or l}.8 L
( ln
2
x }l mL/m
2
~ l},8l6 mL or l }.8 L)
9 L (or 9,uuu mL) 2uu mL/ft
2
~ 7 ft
2
(9,uuu mL 2l} mL/m
2
~ m
2
)
2uu mL/ft
2
29 mL/ft
2
~ 229 mL/ft
2
(2l} mL/m
2
}l mL/m
2
~ 267 mL/m
2
)
Curr ent output of the vater pump 29 mL/ft
2
(}l mL/m
2
~ Nev vater output per
replenlshment cycle
9/91 PROCESS MOHTORHG: CHEMCAL AHD MECHAHCAL PARAMETERS "%
HYDROMETER
CROSSOVER
PROCEDURE
Llke other measurlng lnstruments,
hydrometers have an lnherent varl-
ablllty. Although the varlablllty from
hydrometer to hydrometer ls usually
small, you should run a crossover test
vhen you use a "nev` hydrometer.
To run a crossover test, follov these
steps:
l. Make speclflc-gravlty measure-
ments of at least dlfferent
samples of the same tank solutlon
vlth both the "old` and the "nev`
hydrometer.
2. Determlne the average measure-
ment for each hydrometer by
addlng the measurements and
dlvldlng the result by the number
of readlngs.
}. To calculate the dlfference betveen
the hydrometers, subtract the
smaller average from the larger
average.
If the dlfference betveen the
average readlngs for the hydrometers
ls greater than u.uu2, contact your
Technlcal Sales Representatlve (TSR)
to help you determlne vhlch hydrom-
eter ls correct. If the dlfference ls less
than or equal to u.uu2, start uslng the
"nev` hydrometer.
Nete. Sample calculatlons are glven
at the rlght.
APPENDIX 4B
Example 1
1
2
3
4
5
Total
Measurement
Reading with
Old Hydrometer
Reading with
New Hydrometer
1.063
1.062
1.063
1.062
1.064
5.314
1.062
1.062
1.063
1.063
1.064
5.314
Example 2
1
2
3
4
5
Total
Measurement
Reading with
Old Hydrometer
Reading with
New Hydrometer
1.063
1.062
1.061
1.062
1.064
5.312
1.066
1.065
1.064
1.066
1.066
5.327
.}l
~ l.u628 Average Readlng`old` hydrometer

.}l
~ l.u628 Average Readlng`nev` hydrometer

Dlfference ~ l.u628 l.u628 ~ u, use the "nev` hydrometer.
.}l2
~ l.u62 Average Readlng`old` hydrometer

.}27
~ l.u6 Average Readlng`nev` hydrometer

Dlfference ~ l.u6 l.u62 ~ u.uu} > u.uu2, contact your TSR to
determlne vhlch hydrometer ls correct.

Process Monitoring: Chemical and Mechanical Parameters

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K KK KKOD OD OD OD ODAK Q AK Q AK Q AK Q AK Q-LAB Prcess MnIrng Servce -LAB Prcess MnIrng Servce -LAB Prcess MnIrng Servce -LAB

g Servce -LAB Prcess MnIrng Servce -LAB Prcess MnIrng Servce

~ l.u628 Average Readlng`old` hydrometer

~ l.u628 Average Readlng`nev` hydrometer

~ l.u62 Average Readlng`old` hydrometer

~ l.u6 Average Readlng`nev` hydrometer

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