Installation qualification for pure steam generator

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
ABBREVIATIONSFULL FORM
POPurchase Order
MOCMaterial Of Construction
PLCProgrammable Logic Controller
RPMRotations Per Minute
HPHorse Power
T/CTriclover
FATFactory Acceptance Test
ASMEAmerican Society of Mechanical Engineers
MMIMan Machine Interface
DPDiaphragm
AVAir vent
PGPressure Gauge
SVSafety Valve
STUSteam Trap Unit
  • CHECK POINTS & TESTING
ObjectiveTo check the documents required for job as per checklist.
Material Documents list submitted in the FAT.
MethodThe 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 CriteriaThe documents submitted shall be as specified in the list of reference documents.
  • LIST OF REFERENCE DOCUMENTS
Sr. No.Title Of DocumentSubmittal StageDocument No. Remarks
1.List of the reference drawingsSAT
2.Material history chart with Test CertificatesSAT 

 

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

 

Corrective action

In case of Non Compliance

 

 

 

Conclusions
 Performed byChecked by
Name
Signature
Date
  • LIST OF REFERENCE DRAWINGS
ObjectiveTo check reference drawing required for job against list mention below.
Material Approved drawings list submitted in the FAT
MethodThe 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 CriteriaThe drawings submitted shall be as specified in the list of reference drawing.

 

Sr. No.Title Of DrawingSubmittal StageDrawing No. Rev.Remarks
1. G.A. DrawingSAT
2.P & I DiagramSAT
3.Wiring diagramSAT
4.Pneumatic DiagramSAT
5.Operation Logic DiagramSAT

 

Corrective action

In case of Non Compliance

 

 

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

DR specification/ Approved drawing.

 MaterialMaterial test certificates.
MethodThe submitted certificates shall be checked for correct material usage against the details submitted in the vendor , by the vendor
Acceptance criteriaThe certificates shall prove that the materials used for construction of components are as per the approved specifications.
  • MATERIAL HISTORY CHART
Sr. No.Part Description & SizeAcceptance CriteriaResult Remarks
MaterialCertificate 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”X1.65mmASME BPE 316L

   12.

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

          13.

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

   14.

Steam line: 1.5” NB X SCH 10AISI 304
 
   15.MINI TC GasketSILICON
   16.1/2” T/C GasketSILICON
   17.1” T/C GasketSILICON
   18.2” T/C GasketSILICON
   19.3” T/C GasketSILICON

 

Corrective action

In case of Non Compliance

 

 

 

Conclusions
 Performed byChecked by
Name
Signature
Date
  • BOUGHT – OUT COMPONENTS
ObjectiveTo prove that the Bought Out components used for construction of the equipment are as per the approved specifications.
MaterialBought Out components specification sheets (From the original manufacturer)
MethodInspect the installed component. Compare Quality Certificate of the component the make, Model No. and other specifications with the approved specifications.
Acceptance criteriaThe 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.ComponentMakeCertificate TypeQTY.
MECHANICAL COMPONENTS
1.Feed Pump for feed waterGrundfosTest Certificate01 No.
2.Flow  indicatorKrohne MarshallTest Certificate01 No.
3.Non Return valveAlfa LavalTest Certificate02 No.
4.Pneumatic  valveGemuCompliance Certificate05 Nos.
 5.Sampling valveCrane ProcessTest Certificate01 No.
 6.Diaphragm valveCrane ProcessTest Certificate02  No.
 7.Steam TrapSpiraxTest Certificate04 Nos.
 8.Safety valveSpiraxTest Certificate01 No.
 9.Pressure Gauge for Pure SteamWaareeCalibration Certificate01 No.
 10.Pressure Gauge for Boiler steamWaareeCalibration Certificate01 No.
 11.Pressure Gauge for Feed waterWaareeCalibration Certificate01 No.
 12.Ball ValveShaktiTest Certificate04 Nos.
 13.Air  Pressure RegulatorFestoTest Certificate01 No.
 14.Globe ValveShaktiTest Certificate01No
 15.Vent FilterPallTest Certificate01 NO
 16.Needle ValveShaktiTest Certificate–01 No

 

ELECTRICAL COMPONENTS
1.PLCAllen BradelyTest Certificate01 No.
2.DisplayAllen BradelyTest Certificate01 No.
3.Conductivity meterYokogawaCalibration Certificate01 No.
4.Conductivity sensorYokogawaCalibration Certificate 02 Nos.
5.Temperature SensorRadixCalibration Certificate03 Nos.
6.Pressure switchOrionTest Certificate03  Nos.
7.Liquid level sensor on NCGRPune TechtrolTest Certificate02 No.
8.Liquid level Sensor at ColumnE+HCalibration Certificate01 No.

9.

Pressure TransmiterJumoComplience Certificate01 No
10.Temperature TransmitterRadixCalibration Certificate03Nos

 

Corrective action

In case of Non Compliance

 

 

Conclusions
 Performed byChecked by
Name
Signature
Date
  • COMPONENTS CERTIFICATION & CALIBRATION
ObjectiveTo verify the Test certificates and Calibration certificates of the designated components.
MaterialTest certificates and Calibration certificates of the designated components (From the original manufacturer or from a certified calibration laboratory)
MethodThe 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 criteriaThe verification shall prove that the designated components used for construction of the equipment are properly tested / calibrated.
  • COMPONENTS CERTIFICATION & CALIBRATION
Sr. No.ComponentMakeSr. No. / I.D. NoCertificate 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 MeterYokogawa
 

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 LineRadix
 

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 byChecked by
Name
Signature
Date
  • DIMENSIONAL MEASUREMENTS
ObjectiveDimension check against Approved GA Drawings.
  InstrumentsMeasure Tape 0-3000mm , Vernier Caliper 0- 300 mm,
MethodDirect measurement of Overall dimensions, Connection Points.

Install the plant on the suitable place.

Measure the indicated dimensions and fill in the dimension report.                     

Acceptance CriteriaAll 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.

ParameterValue from Drawing

(mm)

Actual Value

(mm)

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

No.

DescriptionValue from GA Drawing

(mm)

Actual Value

(mm)

Corresponding/

Non corresponding

1Boiler Steam to PSG1.5 ” ASA 150 # Flange
2Compressed air inlet½” BSP FEMALE THD.
3Header Drain1.5” BSP FEMALE THD.
4Drain Header Air Vent1” BSP FEMALE THD.
5Pure steam outlet2” TRICLOVER
6Feed water Inlet1” TRICLOVER

 

Corrective action

In case of Non Compliance

Conclusions
 Performed byChecked by
Name
Signature
Date
  • SURFACE FINISH TESTS
ObjectiveTo check the surface finish of the surface of the plant and to verify against the approved drawing requirement.
InstrumentsVerification of documents submitted by vendor
Acceptance CriteriaAll the surfaces tested shall meet the requirements.

 

Corrective action

In case of Non Compliance

 

 

 

Conclusions
 Performed byChecked by
Name
Signature
Date
  • PLC INPUT OUTPUT CHECK
ObjectiveTo check the Input Output and to verify against the wiring diagram requirement.
MethodCheck the input output against wiring diagram visually during operation.

Results shall be recorded.

Acceptance CriteriaAll the Input and output shall meet the requirements.

 

TEST TO BE CARRIED OUT & PROCEDUREACCEPTANCE CRITERIONRESULTS

( 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 byChecked by
Name
Signature
Date

 

  • SUMMARY REPORT
 

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

 

  •  Conclusions:

 

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