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Operational qualification for pure steam generator

  • OBJECTIVE
  • To establish documentary evidence to demonstrate the Pure Steam Generator  system is qualified for correct operation as per guidelines outlined in this protocol & operational manual.
  • SCOPE OF THIS DOCUMENT
  • This protocol is applicable to pure steam generator.
  • Functional testing (including safety tests) of the equipment with printouts for tests that require supporting documentation.
  • RESPONSIBILITES
  • Inspection
  • Customer or their authorized representatives are responsible for this OQ 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
  • LIST OF REFERENCE DOCUMENTS
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.

 

Sr. No. Title Of Document Submittal Stage Document No. Remarks
1. Hydrostatic Test Report SAT
2. Operation Qualification Report SAT
3. Steam Quality Test Report.

a.  Non Condensable Test Report.

b.  Dryness Faction Test Report.

c.  Degree of superheat Test report.

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

 

Corrective action

In case of Non Compliance

 

 

 

Conclusions
  Performed by Checked by
Name
Signature
Date
  • HYDROSTATIC TEST
Objective To qualify the welding quality in view of Leak-tightness under Hydraulic pressured condition as per the ASME Sec. VIII Div.1 (2010) code and qualifying the vessel to operate at specified design condition.
Method Verification of documents submitted by vendor.
Acceptance criteria No pressure drop or leakage from any joint at specified Hydro test pressure within 30 minutes of observation.

No deformation of the inside surface.

 

Corrective action

In case of Non Compliance

 

 

 

Conclusions
  Performed by Review by \ Checked by
Name
Signature
Date
  • CYCLE OPERATION (RUNNING TRIAL)
SR. NO. TEST TO BE CARRIED OUT & PROCEDURE ACCEPTANCE CRITERION RESULTS

( PASS/ FAIL)

WITH SIGN

  • OPERATION QUALIFICATION
1 EMEREGENCY STOP
Press Emergency Stop Check the display which shows fault “EMERGENCY STOP” and Feed Pump will stop and All Valve will OFF.
Release Emergency Stop Check the display, which shows “PROCESS OK” and Feed pump will start and All Valves will ON.
2 AIR PRESSURE LOW
Set the air pressure switch at higher value than actual air pressure from pressure switch value, Now check on the display, which show fault “AIR PRESSURE LOW ” & All Valves will close and feed pump stop, but GRC to drain valve (Normally open valve) will be open.
Set Air pressure switch at lower value than actual air pressure from pressure switch value, Now check on the display, which show “PROCESS OK “& All valves will open, but GRC to drain valve (Normally open valve) will be close and feed pump start.
3 GRC WATER LEVAL LOW
Stop Air supply given to Feed Water to GC Valve, after some time Check on the display which show fault “GRC WATER LVL LOW” and Feed Pump, Feed Water in PSG Valve will be Stop.
Give Air supply to Pneumatic Feed Water to GC Valve. After some time Check on the displays which show “PROCESS OK” and Feed Pump & Feed Water in PSG valve will be ON after achieving high level in the GRC.
4 BOILER STEAM TEMPERATURE LOW
Close Plant Steam in PSG Valve & wait till the Boiler steam temperature decrease below set temperature. Check on the display it will show “BOI. STEAM TEMP. LOW “& Feed Water in PSG Valve and Feed pump will be OFF and purging valve become ON.
Open Plant Steam in PSG Valve & wait till the Boiler steam temperature increase up to set temperature Check on the display it will show “PROCESS OK “ and Feed Water in PSG Valve and Feed pump will be ON and purging valve become OFF.
5 FEED WATER CONDUCTIVITY HIGH
Decrease the set parameter value (5 microsim /cm) then existing conductivity Check on display which will show alarm “F.W. CONDUCT. HIGH” and feed pump will stop and GRC to drain valve (Normally open valve) will be open.
Increase the set parameter value (5microsim /cm) then existing conductivity Check on display which will show “PROCESS OK” and feed pump will start and GRC to drain valve (Normally open valve) will be close.
6 PURE STEAM CONDUCTIVITY HIGH
Decrease the set parameter value (1microsim /cm) then existing conductivity Check on display which will show alarm “PURE STEAM CONDUCT.  HIGH”
Increase the set parameter value (1microsim /cm) then existing conductivity Check on display which will show “PROCESS OK”
7 FEED WATER PRESSURE  LOW
Turn pressure setting knob clock-wise to set pressure more than actual pressure, till relay of pressure switch gets OFF. Check the display which show “F.W. PRESSURE LOW
Turn pressure setting knob Anti-clock-wise to set pressure less than actual pressure, till relay of pressure switch gets ON. Check the display which shows “PROCESS OK
8 PURE STEAM PRESSURE HIGH
Close the pure steam outlet valve & let the pure steam pressure be increased higher than the set pressure for Pure steam pressure high delay time parameter Check on display which will show “PURE STEAM PRESSURE HIGH” & Feed Water in PSG Valve and Feed pump will OFF
Open the pure steam outlet valve to release the pure steam pressure and display shows ”PROCESS OK”. As soon as pressure decreased lower than the set pressure for the pure steam high pressure parameter, Now let the pressure be decrease till the pure steam pressure is reached to the, pure steam set pressure for the pure steam lower pressure. As soon as the set lower pressure is reached, Feed Water in PSG Valve and Feed pump will ON.
9 PURE STEAM PRESSURE LOW
Open the pure steam outlet valve & let the pure steam pressure be decrease lower than the set pressure for Pure steam pressure low delay time parameter Check on display which will show “PURE STEAM PRESSURE LOW”.
Close the pure steam outlet valve to release the pure steam pressure. As soon as pressure increase higher  than the set pressure for the pure steam low pressure parameter, Now let the pressure be increase till the pure steam pressure is reached to the, pure steam set pressure for the pure steam higher pressure. Display shows “PROCESS OK” As soon as the set higher pressure is reached.
10 PURGING ON PROBLEM
Stop Air supply given to Pneumatic Purging Valve Increase Feed Water flow rate. Allow water to accumulate in column till it reaches to level sensor (float switch). Wait for set parameter Purging Fault ON time (Ensure that this stage will remain continuously) Displays show “PURGING ON PROBLEM” with buzzer & Feed Water in PSG Valve and Feed pump will OFF.
Give Air supply to Pneumatic Purging Valve Now Water will be drained out. Check the displays which show “PROCESS OK”. Purging valve will close after purging time set parameter. If we press ACK during fault condition Feed Water in PSG Valve will remain OFF. Only after draining out water Feed Water in PSG Valve and Feed pump will ON.

 

11 PURGING OFF PROBLEM
Decrease Feed Water Flow rates. Also keep Pneumatic Purging Valve open manually by turning manual operating screw of Solenoid Valve Wait Purging Fault OFF time (settable parameter) (Ensure that this stage will remain continuously for set time & water should not reach to level sensor in column) Display will Show “PURGING OFF PROBLEM ” & Feed Water in PSG Valve and Feed pump will OFF.
Increase Feed Water flow rate & Keep Pneumatic Purging valve in auto operation. Ensure that water should reach up to level sensor. Purging valve will close after purging time set parameter. If we press ACK during fault condition Feed Water in PSG Valve and Feed pump will Start and display shows “PROCESS OK” Even if water level is till high & again fault will generate after same purging fault OFF timer.
12 FEED PUMP OVER LOAD
While pump is running give link between 24VDC and Feed Pump O/L i/p, Immediately feed pump will stops automatically Check the fault on display “FEED PUMP O/L“.
Now Again remove link between them. As soon as contact of relay gets on Feed pump will starts automatically Check the Display which shows the “PROCESS OK”.
13 INSUFF.FEED WATER
  Turn pressure setting knob clock-wise to set pressure more than actual pressure, till relay of pressure switch gets OFF. Check the display which shows “INSUFF. FEED WATER”.  
Turn pressure setting knob Anti-clock-wise to set pressure less than actual pressure, till relay of pressure switch gets ON. Check the display which shows “PROCESS OK  
14 POWER FAILURE
Switch OFF main panel Entire panel will off and cycle will stop.
Switch ON main panel Now check on the print, which show “POWER FAIL”. After Power ON Process will start from same phase from where it is interrupted.
  • INTER LOCKING
1. FEED WATER VALVE IN PSG (PN1) AND FEED PUMP (P1) Boi. Steam Temp. Low
Pure steam Pressure High
Purging ON problem
Purging OFF problem
Air pressure low.
Emergency stop.
High Level Delay Time
Feed water Conductivity High
2. PURGING VALVE (PN1) Column water level high
Boiler steam temperature low.
Purging Time
3. FEED WATER TO G.C VALVE Air Pressure Low
GRC Water Leval High
Emergency Stop
4. GRC TO GC VALVE Air Pressure Low
Emergency Stop
Process stop
5. GRC TO DRAIN VALVE Air Pressure Low
Process stop

 

Corrective action in case of Non Compliance  

 

 

Conclusion
  Performed by Checked by
Name
Signature
Date
  • OPERATION SEQUENCE TEST REPORT
Objective To carry out plant Operation sequence for observing performance/operation of all the items this are installed on the plant.
Method Perform the operations sequence as indicated in manual.
Acceptance Criteria (Refer attached Form).

 

SR.

NO.

TEST TO BE CARRIED OUT & PROCEDURE ACCEPTANCE CRITERION RESULTS

(PASS/FAIL)

WITH SIGN

1 Check operation sequence according to procedure given in operation and maintenance manual. As specified in Operation and Maintenance manual.

 

Corrective action in case of Non Compliance  

 

Conclusion
  Performed by Checked by
Name
Signature
Date
  • STEAM QUALITY TEST REPORT
Objective To carry out test of steam quality test.
Method Perform the test according to EN285.
Acceptance Criteria (Refer attached Form).

 

SR. NO. TEST TO BE CARRIED OUT ACCEPTANCE CRITERION RESULTS

( PASS/ FAIL)

WITH SIGN

1. Non Condensable Test Report. It should not more then 3.5 %
2. Dryness Fraction Test Report. It should not less then 0.9
3. Degree of Superheat Test Report.

 

The degrees of super heat measured in free steam at atmospheric pressure shell not exceed 25° C

 

Corrective action in case of Non Compliance  

 

 

Conclusion
  Performed by Checked by
Name
Signature
Date
  • SUMMARY REPORT
  • Summary of  the results obtained during OQ:   
  • Significant deviations observed during OQ:
 Conclusions:

 

 

 

 

 

 

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