INSTALLATION QUALIFICATION PROTOCOL AIR COMPRESSOR
PROTOCOL APPROVAL
THE IQ PROTOCOL FOR AIR COMPRESSORS, HAS BEEN REVIEWED AND APPROVED FOR IMPLEMENTATION BY AUTHORISED PERSONNEL FROM THE FOLLOWING DEPARTMENTSPrepared by:
CONTENTS
| INSTALLATION QUALIFICATION |
| 1. OBJECTIVE / PURPOSE |
| 2. EQUIPMENT DESCRIPTION, IDENTIFICATION, AND CHECKS |
| 3. MAJOR COMPONENTS |
| 4. EQUIPMENT CONTROL SYSTEM |
| 5. SAFETY QUALIFICATION |
| 6. UTILITIES AND SERVICES REQUIRED |
| 7. LIST OF SPARE PARTS |
| 8. INSTALLATION VERIFICATION |
| 9. DESCRIPTION OF NON CONFORMANCE |
| 10. INSTALLATION QUALIFICATIONS – DISCUSSIONS AND RECOMMENDATIONS |
TYPE: RECIPROCATING,2 STAGE,NON LUBRICATE, CAPACITY: 500 CFM
LOCATION : FORMULATIONS UNIT, SERVICE BLOCK
OBJECTIVE / PURPOSE
INSTALLATION QUALIFICATION:
To establish documented evidence that the AIR COMPRESSOR is installed as per the Design specifications, Manufacturer’s recommendations and Process requirements, complies with standard operating procedures and cGMP requirements at Pharmaceutical company.
ACCEPTANCE OF INSTALLATION INCLUDES,
- Installation of the equipment with suitable utility connections.
- Equipment meets the current Good Manufacturing Practice (cGMP) requirements.
- Installation of the equipment compliance with Design specifications and safety considerations.
- Installation of Auxiliary equipment with suitable Utility connections.
EQUIPMENT DESCRIPTION AND IDENTIFICATION:
DESCRIPTION – ASSEMBLY:
Air compressor with LP& HP Cylinders: It is responsible for handling the air concerning the receival of fresh air (after filtration), compression of first stage in LP cylinder and second stage compression in HP cylinder, cooling and distribution to the respective areas.
Air compressor Inter Cooler Section: The air is passed through intercooler section where air temperature will be reduced & moisture shall condensate .
Air compressor After Cooler Section: The air passed through a aftercooler section where air temperature will be reduced & moisture will be condensates.
Air compressor Receiver tank: It provides momentary reserve capacity, to improve regulation and to ensure a smooth flow through out the system.
Air Dryer: It removes the moisture content (water vapor) present in the air prior sending to respective areas.
Air compressor Electrical Section: The total Air compressor system is operated from electrical control panel.
Air Distribution piping, valves and filters: This is involved in the distribution of the processed filtered air to the specified areas. It also provide a mechanism of controlling the air volume as per the requirement of the areas during the normal run.
MAJOR COMPONENTS
| Sr. No. | Description |
| 1. | Air compressor with LP& HP cylinders |
| 2. | Inter cooler, section |
| 3. | After cooler section |
| 4. | Receiver tank |
| 5. | Electrical control section |
| 6. | Air dryer |
| 7. | Air distribution – piping, valves, and filters |
MAJOR COMPONENTS
Name of the component: Compressor with LP& HP cylinders
| Description | Specified |
| Motor | |
| Make | Crompton Greaves |
| Sr. No. | |
| KW/HP | 75/100 |
| RPM | 1480 |
| Pulley size | 12” |
| Full load Amps. | 123 A |
| Insulation Class | F |
| Installation Consideration | Status (Yes/No) |
| Properly mounted, supported & connected | |
| Properly labeled / Identified ( To be verified with PI- diagram) |
| Documentation | Attached (Yes/No) |
| Component Data / P.O Specifications for basic unit | |
| Test Certificates |
Name of the component: Compressor
| Description | Specified | Actual | |
| Make | Ingersoll-rand | ||
| CFM | 500 | ||
| Location | Utility block | ||
| CYLINDER (LOW PRESSURE) | |||
| TYPE | NON LUBRICATED | ||
| CAPACITY | 1.8 KG /SQ CM | ||
| CYLINDER (HIGH PRESSURE) | |||
| TYPE | NON LUBRICATED | ||
| CAPACITY | 7.5 KG /SQ CM | ||
| FLY WHEEL SIZE | 28” | ||
| Installation Consideration | Status (Yes/No) |
| Properly mounted, supported & connected | |
| Properly labeled / Identified ( To be verified with PI- diagram) |
| Documentation | Attached (Yes/No) |
| Component Data / P.O Specifications for basic unit | |
| Test Certificates |
Name of the component: Inter cooler & after cooler Section
| Description | Specified |
| Inter cooler Section | |
| Make | Ingersoll-rand |
| Capacity | Shell-8.08 kg/sq cm tube-4.21 kg/sq cm |
| Code no | A-129/aeh-99056/36 |
| Type | Shell &air tube |
| Installation Consideration | Status (Yes/No) |
| Properly mounted, supported & connected | |
| Properly labeled / Identified ( To be verified with PI- diagram) |
| Documentation | Attached (Yes/No) |
| Component Data / P.O Specifications for basic unit | |
| Test Certificates |
Name of the component: Inter cooler & after cooler Section
| Description | Specified |
| After cooler Section | |
| Make | AERO-ENGINEERS |
| Capacity | Shell-6 kg/sq cm tube-12 kg/sq cm |
| Code no | RIN 7699T6 |
| Serial no | AE:6073 |
| Type | Shell &air tube |
| Installation Consideration | Status (Yes/No) |
| Properly mounted, supported & connected | |
| Properly labeled / Identified ( To be verified with PI- diagram) |
| Documentation | Attached (Yes/No) |
| Component Data / P.O Specifications for basic unit | |
| Test Certificates |
Name of the component: Air receiver tank
| Description | Specified | Actual |
| Make | Premier engg.equip. | |
| Type | Vertical position. | |
| MOC | M .S | |
| Total Nos. | 1 | |
| Dimensions | 30×93.5×6/8 mm | |
| Working Pressure | 150 PSIG | |
| Capacity | 1 cubic meter |
| Installation Consideration | Status (Yes/No) |
| Properly mounted, supported & connected | |
| Properly labeled / Identified ( To be verified with PI- diagram) |
| Documentation | Attached (Yes/No) |
| Component Data / P.O Specifications for basic unit | |
| Test Certificates |
Name of the component: Air dryer Section
| Description | Specified | Actual |
| Make | Sanpar | |
| type | Mechanical refrigeration | |
| Capacity | Dew point 2 –4 °c | |
| Full load Amps | 123 amps |
| Installation Consideration | Status (Yes/No) |
| Properly mounted, supported & connected | |
| Properly labeled / Identified ( To be verified with PI- diagram) |
| Documentation | Attached (Yes/No) |
| Component Data / P.O Specifications for basic unit | |
| Test Certificates |
Name of the component: Air Distribution – Piping, Valves, & Filters
| Description | Specified | Actual |
| i) Supply Pipes | ||
| MOC | G.I | |
| CLASS | “C” | |
| SIZE | As per design specification | |
| ii) Valves | ||
| MOC | Cast iron | |
| TYPE | Ball valves | |
| MAKE | Aduco | |
| iii) Supply Air Filters | ||
| MAKE | Sanpar | |
| MOC | Sintered bronze | |
| SIZE | 5 micron | |
| LOCATION | Before air dryer | |
| iv) Supply Air Filters | ||
| MOC | Sintered bronze | |
| MAKE | Sanpar | |
| SIZE | 0.1 micron | |
| LOCATION | After air dryer. | |
| Installation Consideration | Status (Yes/No) |
| Properly mounted, supported & connected | |
| Properly labeled / Identified( To be verified with PI- diagram) |
| Documentation | Attached (Yes/No) |
| Component Data / P.O Specifications for basic unit | |
| Test Certificates |
Name of the component: Filters
| Description | Specified | Checked By | ||
| i) Suction side filter | ||||
| Make | Ingersoll-rand. | |||
| Capacity | 20 micron | |||
| Type | Dry type – 2 stage | |||
| MOC | Paper-element | |||
| ii) Suction side filter | ||||
| Make | Ingersoll-rand. | |||
| Capacity | 20 micron | |||
| Type | Dry type – 2 stage | |||
| MOC | Paper-element | |||
| Installation Consideration | Status (Yes/No) |
| Properly mounted, supported & connected | |
| Properly labelled / Identified ( To be verified with PI- diagram) |
| Documentation | Attached (Yes/No) |
| Component Data / P.O Specifications for basic unit | |
| Test Certificates |
Name of the component: Electrical controls Section
| Description | Specified | Actual |
| Make | Allenbradely | |
| Flame proofing | Not applicable | |
| Signal Indicators | RYB | |
| Full load Amps | 123 amps |
| Installation Consideration | Status (Yes/No) | Checked By |
| Properly mounted, supported & connected | ||
| Properly labelled / Identified ( To be verified with PI- diagram) |
| Documentation | Attached (Yes/No) | Checked By |
| Component Data / P.O Specifications for basic unit | ||
| Test Certificates |
4.0 EQUIPMENT CONTROL SYSTEM:
Equipment shall be controlled by independent electrical panels located near the Air Handling Unit.
Control panel consists of the following,
| Description | Specified | Actual | Checked By |
| Indicator for Main On | Three R Y B Indicators | ||
| Auto /Manual selector switch | To operate in Auto or Manual |
SAFETY QUALIFICATION
| S.NO. | CHECK | OBSERVATION | CHECKED BY |
| 1.0 | LOCATION | ||
| 2.0 | SAFETY GUARDS FOR MOVING PARTS | ||
| 3.0 | SAFETY INTERLOCKS | ||
| 4.0 | EARTHING | ||
| 5.0 | SERVICES | ||
| a. ELECTRICITY | |||
| b. COOLING WATER | |||
| 6.0 | NOISE | ||
| 7.0 | VIBRATION | ||
| 8.0 | LIGHTING | ||
| 9.0 | SIGNS | ||
| 10.0 | PRESSURE TESTING | ||
| 11.0 | SAFETY ALARMS | ||
| 12.0 | EMERGENCY STOP ACCESSIBLE | ||
UTILITIES AND SERVICES REQUIRED
| Sr .No | REQUIREMENTS | SUPPLIERS SPECIFICATION | VERIFICATION |
| 1. | Electrical network
| 415 V/50 cs/3 Phase AC supply through suitable isolator | |
| 2. | Electrical backup system | Optional | |
| 3. | Lighting | Not Specified | |
| 4. | Cooling water for inter Cooler , after cooler and Cylinder jackets | From cooling tower. | |
| 5. | Lubrication | To crank shaft, case, and internal moving parts. | |
| 6. | Log Sheets | Optional |
LIST OF SPARE PARTS:
| S.No. | Description of Spares | Quantity |
| 1. | Air filter | 1z |
| 2. | Piston rings | 2 |
| 3. | Wearing | 1 |
| 4. | Loading valve | 1 |
| 5. | Discharge valve | 1 |
| 6. | Servo 220 oil | 100Ltrs |
| 7. | Auxiliary valve | 1 |
| 1. | Scrapper rings | 1 set |
Refer section supplier’s manual for code number of spares and other spares
INSTALLATION VERIFICATION:
Installation Verification Check List
| S.No. | Consideration | Actual | Checked By |
| 1 | Major components are securely anchored and protected from shock | ||
| 2 | There is no observable physical damage | ||
| 3 | Sufficient room for servicing provided. | ||
| 4 | Electrical connections have been done according to the drawings and grounded. | ||
| 5 | Equipment identification nameplate is visible. | ||
| 6 | Units installed on foundation and secured in place as per manufacturer’s recommendations. | ||
| 7 | The equipment is furnished with proper earthing arrangements. | ||
| 8 | Air receiver tank installed with all necessary instruments | ||
| 9 | Chilled water supply properly connected | ||
| 10 | Safety valve is provided for air receiver |
Description Of Non- Conformance of related parts
| S. No. | Specifications | Actual | Probable reasons | Checked by |
| 1. |
Correction of Non-Conformance
| S. No. | Correction Done | Done by | Checked by |
| 1. |
9.2 Compliance Report
| S. No. | Description of conformance | Checked by | Remarks |
| 1. |
10.0 INSTALLATION QUALIFICATION
10.1 Discussions:
10.2 Recommendations:
Team:
| Department | Name | Signature | Date |
| Validation | |||
| Production | |||
| Services | |||
| Quality Assurance |