Installation qualification for pure steam generator

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Installation qualification for pure steam generator

  • OBJECTIVE
  • To confirm, by physical inspection and testing, that the fabrication and assembly of the equipment and any auxiliary support systems, conforms to the Design parameters as per the Design Review.
  • SCOPE 
  • The tests shall be carried out at customer place.
  • The verification of compliance to specifications as per vandor documents and to GMP requirements.
  • Confirmation that all design Documents, specifications and test certificates are approved, available and accurate.
  • Physical Inspection of the electrical hardware.
  • Mechanical inspection of the construction of the equipment.
  • RESPONSIBILITES
  • Inspection
  • Customer or their authorized representatives are responsible for this IQ document
  • All documents shall be checked and approved by customer or their authorized representatives.
  • Production personal will perform this test.
  • ABBREVIATIONS
ABBREVIATIONS FULL FORM
PO Purchase Order
MOC Material Of Construction
PLC Programmable Logic Controller
RPM Rotations Per Minute
HP Horse Power
T/C Triclover
FAT Factory Acceptance Test
ASME American Society of Mechanical Engineers
MMI Man Machine Interface
DP Diaphragm
AV Air vent
PG Pressure Gauge
SV Safety Valve
STU Steam Trap Unit
  • CHECK POINTS & TESTING
Objective To check the documents required for job as per checklist.
Material  Documents list submitted in the FAT.
Method The submitted documents shall be checked for correct Documents No., version No., date and authorization details against the details submitted in the FAT Test form by the vendor
Acceptance Criteria The documents submitted shall be as specified in the list of reference documents.
  • LIST OF REFERENCE DOCUMENTS
Sr. No. Title Of Document Submittal Stage Document No. Remarks
1. List of the reference drawings SAT
2. Material history chart with Test Certificates SAT  

 
3. Bought – out components SAT
4. Components certification & calibration. SAT
5. Dimensional report SAT
6. Surface finish report SAT

 

Corrective action

In case of Non Compliance

  

 

 
Conclusions
  Performed by Checked by
Name
Signature
Date
  • LIST OF REFERENCE DRAWINGS
Objective To check reference drawing required for job against list mention below.
Material  Approved drawings list submitted in the FAT
Method The submitted Drawings shall be checked for correct Drawings No., version No., date and authorization details against the details submitted in the FAT Test form by the vendor. Record all the data on Form.                                                    
Acceptance Criteria The drawings submitted shall be as specified in the list of reference drawing.

 

Sr. No. Title Of Drawing Submittal Stage Drawing No. Rev. Remarks
1.  G.A. Drawing SAT
2. P & I Diagram SAT
3. Wiring diagram SAT
4. Pneumatic Diagram SAT
5. Operation Logic Diagram SAT

 

Corrective action

In case of Non Compliance

  

 
Conclusions
  Performed by Checked by
Name
Signature
Date
  • MATERIAL HISTORY CHART
Objective To prove that the materials used for construction of components are as per the

DR specification/ Approved drawing.
 Material Material test certificates.
Method The submitted certificates shall be checked for correct material usage against the details submitted in the vendor , by the vendor
Acceptance criteria The certificates shall prove that the materials used for construction of components are as per the approved specifications.
  • MATERIAL HISTORY CHART
Sr. No. Part Description & Size Acceptance Criteria Result Remarks
Material Certificate No.
    1. Column Shell

14 SWG Sheet

 ASTM A240M

GR316L
    2. Condenser Shell

14 SWG Sheet

 ASTM A240M

GR316L
    3. Condenser Tubes

12.7 MM  OD X 1 MM Thk. Tube

  SA213 TP316L
    4. Pre heater Shell

3” OD X 16 SWG Pipe

 AISI 304
    5. Pre heater Tubes

12.7 MM  OD X 1 MM  Thk. Tube

  SA213 TP316L
    6. Sampling Pre heater Shell

3”OD X 16 SWG Pipe

 AISI 304
    7. Sampling Pre heater Tubes

¾” OD X 16 SWG Pipe

 SA 249 TP 316L
    8. Separator Fabrication

20 SWG SHEET

 ASTM A240M

GR316L
 
    9. Pure steam Outlet :

2”X 1.65mm Pipe

 ASME BPE 316L
   10. Pure Steam Sampling line

0.5” X 1.65 mm Thk. Tube

 ASME BPE 316L
   11. Interconnecting pipe line& WFI outlet line:0.5”X1.65mm ASME BPE 316L

   12.

 Purified water in and out line:0.5”X1.65mm ASME BPE 316L

          13.

 Preheater assembly to condenser sensor bowl line:1”X1.65mm ASME BPE 316L

   14.

 Steam line: 1.5” NB X SCH 10 AISI 304
 
   15. MINI TC Gasket SILICON
   16. 1/2” T/C Gasket SILICON
   17. 1” T/C Gasket SILICON
   18. 2” T/C Gasket SILICON
   19. 3” T/C Gasket SILICON

 

Corrective action

In case of Non Compliance

  

 

 
Conclusions
  Performed by Checked by
Name
Signature
Date
  • BOUGHT – OUT COMPONENTS
Objective To prove that the Bought Out components used for construction of the equipment are as per the approved specifications.
Material Bought Out components specification sheets (From the original manufacturer)
Method Inspect the installed component. Compare Quality Certificate of the component the make, Model No. and other specifications with the approved specifications.
Acceptance criteria The verification shall prove that the Bought Out components used for construction of the equipment is as per the approved specifications.
  • BOUGHT OUT COMPONENTS
Sr. No. Component Make Certificate Type QTY.
MECHANICAL COMPONENTS
1. Feed Pump for feed water Grundfos Test Certificate 01 No.
2. Flow  indicator Krohne Marshall Test Certificate 01 No.
3. Non Return valve Alfa Laval Test Certificate 02 No.
4. Pneumatic  valve Gemu Compliance Certificate 05 Nos.
 5. Sampling valve Crane Process Test Certificate 01 No.
 6. Diaphragm valve Crane Process Test Certificate 02  No.
 7. Steam Trap Spirax Test Certificate 04 Nos.
 8. Safety valve Spirax Test Certificate 01 No.
 9. Pressure Gauge for Pure Steam Waaree Calibration Certificate 01 No.
 10. Pressure Gauge for Boiler steam Waaree Calibration Certificate 01 No.
 11. Pressure Gauge for Feed water Waaree Calibration Certificate 01 No.
 12. Ball Valve Shakti Test Certificate 04 Nos.
 13. Air  Pressure Regulator Festo Test Certificate 01 No.
 14. Globe Valve Shakti Test Certificate 01No
 15. Vent Filter Pall Test Certificate 01 NO
 16. Needle Valve Shakti Test Certificate– 01 No

 

ELECTRICAL COMPONENTS
1. PLC Allen Bradely Test Certificate 01 No.
2. Display Allen Bradely Test Certificate 01 No.
3. Conductivity meter Yokogawa Calibration Certificate 01 No.
4. Conductivity sensor Yokogawa Calibration Certificate  02 Nos.
5. Temperature Sensor Radix Calibration Certificate 03 Nos.
6. Pressure switch Orion Test Certificate 03  Nos.
7. Liquid level sensor on NCGR Pune Techtrol Test Certificate 02 No.
8. Liquid level Sensor at Column E+H Calibration Certificate 01 No.

9.

 Pressure Transmiter Jumo Complience Certificate 01 No
10. Temperature Transmitter Radix Calibration Certificate 03Nos

 

Corrective action

In case of Non Compliance

  

 
Conclusions
  Performed by Checked by
Name
Signature
Date
  • COMPONENTS CERTIFICATION & CALIBRATION
Objective To verify the Test certificates and Calibration certificates of the designated components.
Material Test certificates and Calibration certificates of the designated components (From the original manufacturer or from a certified calibration laboratory)
Method The Vendor shall present Test certificates and Calibration certificates of the designated components (From the original manufacturer or from a certified calibration laboratory) for verification.

Check whether the certificate corresponds to the installed component.

Compare the make, Model No. and other specifications from the certificate with the specifications of the component and in the table below.

·National traceability certificate to be provided if committed in DR.
Acceptance criteria The verification shall prove that the designated components used for construction of the equipment are properly tested / calibrated.
  • COMPONENTS CERTIFICATION & CALIBRATION
Sr. No. Component Make Sr. No. / I.D. No Certificate No.
MECHANICAL COMPONENTS
 

1.

 Feed Pump(CRN 3 -12)At the inlet of the feed water to PSG (MP1) Grundfos
 

2.

 Variable areaIndicator(KM25-P)100 – 1000 LPHAt discharge side of Feed pump (FI1) Krohne Marshall
 

3.

 Pneumatic  valve (DN 15 )At column purging water line (PNA1) Gemu
 

4.

 Pneumatic  valve (DN 15 / DN 20) At discharge of Feed Pump (PND3) Gemu
 

5.

 Pneumatic Valve (DN 15) At Feed Water In gas cooler (PND1) Gemu
 

6.

 Globe valve At inlet of the plant steam (GV1) Shakti
 

7.

 Non return valve (DN 25 )At Pure Steam Sampling Line (NRV1) Alfa Laval
 

8.

 Non return valve (DN 25) At vacuum break line of GRC (NRV2) Alfa Laval
 

9.

 Diaphragm valve (DN 15 ) At Feed Water Inlet to PSG Line (DP1) Gemu
 

10.

 Diaphragm valve (DN 15 )At feed water inlet (DP2) Gemu
 

11.

 Air regulator At the Inlet of the compressed air (APR1) Festo
 

12.

 Steam Trap BPT-21,15 NB At First column air vent line (ST2) Spirax
 

13.

 Steam Trap BPT-21,15 NB At Plant Steam Condensate Drain of PH1(ST3) Spirax
 

14.

 Steam Trap FT-14CI-10 (c), 15 NB At Boiler Steam Condensate line of first condenser (ST1) Spirax
 

15.

 Safety valve SV11 75-125 PSI At inlet of the plant steam line (SV1) Spirax
 

16.

 Pressure Gauge (0-16 Kg/cm2 )At plant steam line (PG1) Waaree
 

17.

 Pressure Gauge (0-16 Kg/cm2 )At discharge side of feed pump (PG2) Waaree
 

18.

 Pressure Gauge( 0-7 Kg/Cm2 )At pure steam line (PG3) Waaree
 

19.

 Manual ballvalve ½”At plant steam condensate drain through steam trap (BV2) Shakti
 

20.

 Manual ballvalve ½”At plant steam condensate drain by pass to steam trap (BV1) Shakti
 

21.

 Manual ballvalve ½”At the steam inlet to preheater (BV3) Shakti
 

22.

 2 Way Pneumatic valve “NO” Type( DN 15) For gas removal column drain (PNANO) Gemu
 

23.

 Pneumatic Valve (DN 15) At gas removal column to gas cooler (PNA2) Gemu
 

24.

 Disposable Vacuum break Filter (KA1PFRP1 )At top of GRC (VF1) Pall
 

25.

 Plate type Heat Exchanger For drain cooling (PHE1) Swep International
 

26.

 Manual ballvalve (½”)At the pure steam  sample taking line (BV4) Shakti
 

27.

 Pneumatic ValveDN 25At the cooling water of heat exchanger PNA3) Burket
 

28.

 Needle valve ½” At the sampling preheater line for conductivity (NV1) Shakti
 

29.

 Diaphragm valve( DN 25) At the  sample taking line (DP3) Gemu
ELECTRIAL COMPONENTS
 

1.

 PLC:

 

 1762IR4

1766LX32BA

 Allen Bradely
 

2.

 DISPLAY: Allen Bradely
 

3.

 Conductivity Meter Yokogawa
 

4.

 Conductivity sensor At inlet of machine (CS1) Yokogawa
 

5.

 Conductivity Sensor At Pure Steam Condensate Sampling Point (CS2) Yokogawa
 

6.

 Temperature sensor (-50 to 200o C) Boiler steam line (TS1) Radix
 

7.

 Temperature sensor (-50 to 200o C) Pure Steam Line (TS2) Radix
 

8.

 Temperature sensor (-50 to 200o C) Pure Steam Line Radix
 

9.

 Pressure Transmitter( -1 to 5 Bar G )Pure Steam Line (PT1) Jumo
 

10.

 Pressure Switch (0.5 -7.0 Bar) At air pressure Line (PS1) Orion
 

11.

 Pressure Switch (0.5 -7.0 Bar) Pure steam Line (PS2) Orion
 

12

 Pressure Switch (0.2-2.6Bar) at the inlet side of feed water (PS3) Orion
 

13

 Pressure Switch (1-15 Bar) For GRC to PH2 (PS4) Orion
 

14

 Liqued  Level  Sensor (FLT-20H )On column (LS1) E+H

 

Corrective action

In case of Non Compliance

  

 
Conclusions
  Performed by Checked by
Name
Signature
Date
  • DIMENSIONAL MEASUREMENTS
Objective Dimension check against Approved GA Drawings.
  Instruments Measure Tape 0-3000mm , Vernier Caliper 0- 300 mm,
Method Direct measurement of Overall dimensions, Connection Points.

Install the plant on the suitable place.

Measure the indicated dimensions and fill in the dimension report.                     
Acceptance Criteria All the measured dimensions shall be within the dimensional tolerances.
  • UTILITY CONNECTIONS CHECKS
  • HEIGHT (H), LENGTH (L), WIDTH (W)
  • OVERALL DIMENTION:
  • DIMENSION CHECKS
  • CHECK DIMENSION AGAINST GA DRAWING.
  • DIMENSIONAL MEASUREMENTS
Sr.

No.

 Parameter Value from Drawing

(mm)

 Actual Value

(mm)

 Conclusion
1  Overall height   H
2  Overall Width   W
3  Overall Depth   D
4 Pure Steam Outlet Height
  • UTILITY CONNECTION POINTS CHECKS
Sr.

No.

 Description Value from GA Drawing

(mm)

 Actual Value

(mm)

 Corresponding/

Non corresponding
1 Boiler Steam to PSG 1.5 ” ASA 150 # Flange
2 Compressed air inlet ½” BSP FEMALE THD.
3 Header Drain 1.5” BSP FEMALE THD.
4 Drain Header Air Vent 1” BSP FEMALE THD.
5 Pure steam outlet 2” TRICLOVER
6 Feed water Inlet 1” TRICLOVER

 

Corrective action

In case of Non Compliance
Conclusions
  Performed by Checked by
Name
Signature
Date
  • SURFACE FINISH TESTS
Objective To check the surface finish of the surface of the plant and to verify against the approved drawing requirement.
Instruments Verification of documents submitted by vendor
Acceptance Criteria All the surfaces tested shall meet the requirements.

 

Corrective action

In case of Non Compliance

  

 

 
Conclusions
  Performed by Checked by
Name
Signature
Date
  • PLC INPUT OUTPUT CHECK
Objective To check the Input Output and to verify against the wiring diagram requirement.
Method Check the input output against wiring diagram visually during operation.

Results shall be recorded.
Acceptance Criteria All the Input and output shall meet the requirements.

 

TEST TO BE CARRIED OUT & PROCEDURE ACCEPTANCE CRITERION RESULTS

( PASS/ FAIL)

WITH SIGN
Check the input output against wiring diagram visually during operation. All the Input and output shall meet the requirements.

 

Corrective action

In case of Non Compliance

  

 

 
Conclusions
  Performed by Checked by
Name
Signature
Date

 

  • SUMMARY REPORT
 

  • Summary of  the results obtained during IQ:    
  • Significant deviations observed during IQ: 

 

  •  Conclusions:

 

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