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Operational qualification for WFI generation plant

  • OBJECTIVE
  • To establish documentary evidence to demonstrate the WS system is qualified for correct operation as per guidelines outlined in this protocol & operational manual
  • SCOPE OF THIS DOCUMENT
  • This protocol is applicable to multi column water.
  • RESPONSIBILITES
  •  Inspection
  •  Customer or their authorized representatives are responsible for this SAT document.
  • All documents shall be checked and approved by QA 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 SAT.
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
  • LIST OF REFERENCE DRAWINGS
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. PLC Logic Diagram SAT

 

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 (2013) code and qualifying the vessel to operate at specified design condition.
Method 1.Prepare the tank for the shell Hydrostatic test

Fill the Shell side or jacket side/ coil/ tube side parts for which weld joints are to be tested with water. Blind  off all nozzles,

2.Fit the PG with vent valve on top nozzle.

3.Connect Hydraulic pump to nozzle.

4.When water flows out of vent, close the vent valve and develop pressure by pump till PG shows reading at specified Hydrostatic-test pressure.

5.Mark the Pressure on the pressure gauge and check the same after 30 minutes.

6.Check all weld joints & temporary / permanent joints for leakage. Check the internal surface critically for deformity. Record all the data  on Hydrostatic Test Report

Acceptance criteria No pressure drop or leakage from any joint at specified Hydrostatic test pressure within 30 minutes of observation.

No deformation of the inside surface.

 

Corrective action

In case of Non Compliance

 

 

Conclusions
  Performed 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

1 EMERGENCY STOP
  Press Emergency Stop. Feed Pump and Cooling Pump will stop, all valves will get OFF & dumping valve will get ON as per valve position check the display which shows fault “EMERGENCY STOP “
Release Emergency Stop. Feed pump and Cooling Pump will restart, valves will get ON as per interlocking & dumping valve will get OFF. Check display, it shows “PROCESS OK”.
2 AIR PRESSURE LOW
  Set air pressure switch at higher value than actual air pressure. Feed Pump and Cooling Pump will stop, all valves will get OFF & duping valve will get ON. Check on the display, which show fault “AIR PRESSURE LOW”
Set Air pressure switch at lower value than actual air pressure. Feed pump and Cooling Pump will restart, valves will get ON as per interlocking & dumping valve will get OFF. Now check on the display, which show “PROCESS OK”
3 BOILER STEAM TEMPERATURE LOW
  Close the Plant Steam valve & wait till the Plant steam temperature is lower than the set plant steam temperature. Feed Pump will stop after 5 minutes & dumping valve will get ON. Check on the displays which show “BOI.STEAM TEMP. LOW”
Open the Plant Steam valve & wait till the Plant steam temperature is increase than the set plant steam temperature. Feed pump will restart, & dumping valve will get OFF. Check on the displays which show  “PROCESS OK”.
4 DISTILL WATER LEVEL HIGH
  Disconnect wire loop given in panel board for Auxiliary input, Feed pump will stop Check the display which show “DISTILL WATER LVL HIGH”
Now connect wire loop given in panel board for Auxiliary input, Feed pump will restart Check the display which show  “PROCESS OK”
5 FEED WATER SUCTION PRESSURE LOW
  Decrease Feed water inlet pressure less than required pressure. As soon as water pressure becomes less than required, Feed Pump will stop check on the display which show fault “INSUFF. FEED WATER”
Increase Feed water inlet pressure so that pressure is maintained. Feed Pump will restart check on the displays which show  “PROCESS OK”.
6 FEED WATER CONDUCTIVITY HIGH
  Decrease the conductivity setting of feed water set point less than the actual feed water conductivity. Feed Pump will stop check on the display which show fault “F.W. CONDUCT. HIGH”
Increase the conductivity setting of feed water set point more than the actual feed water conductivity. Feed Pump will restart check on the display which show fault  “PROCESS OK“
7 FEED WATER DISCHARGE PRESSURE LOW
  Turn pressure setting knob clock-wise to set pressure more than actual pressure, Check the display which show fault “F. W. PRESSURE LOW”.
Turn pressure setting knob Anti-clock-wise to set pressure less than actual pressure. Check the display which shows “PROCESS OK “.
8 INSUFFICIENT EVAPORATION
  Increase Feed water flow rate than actual required at standard temp of Boiler steam. Now accumulation of Feed water in first column will starts. Wait till water level reaches to level sensor, as soon as water reaches to level sensor, Feed Pump will stop. Check on the display which show fault “INSUFF. EVAPORATION”. (If we close the Ball valve connected before the steam trap which also result to increase accumulation of Feed water in first column)
Now reduce Feed water flow rate and set it standard flow rate required at standard temperature Of Boiler steam. Open the manual drain valve and drain out all water from the first column. Feed Pump will restart. check on the display which show  “PROCESS OK”
9 PURGING ON PROBLEM
  Stop Air supply given to Pneumatic Purging Valve. Increase Feed Water flow rate. Allow water to accumulate in Last column till it reaches to level sensor (float switch). If high level continue more than the Purging Fault ON time Feed Pump will stop. Displays show “PURGING ON PROBLEM”
Give Air supply to Pneumatic Purging Valve. Now Water will be drained out. Check the displays which show “PURGING ON PROBLEM – RELEASE” “PROCESS OK”. Purging valve will close after purging time set parameter. If we press Acknowledge during fault condition Feed Pump will remain stop .Only after draining out  water Feed pump will start.
10 PURGING OFF PROBLEM
  Decrease Feed Water Flow rates. Also keep Pneumatic Purging Valve open manually by turning manual operating screw of Solenoid Valve. If high level not come continues more than Purging Fault OFF time Feed Pump will stop. Display will Show “PURGING OFF PROBLEM”.
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 Acknowledge during fault condition Feed Pump will restart. Even if water level is till high & again fault will generate after same purging fault OFF timer.
11 W.F.I CONDUCTIVITY HIGH
  Decrease the set parameter value than existing conductivity. Dumping valve will ON to reject W.F.I check on display which will Show. “W.F.I. CONDUCT. HIGH”
Increase the set parameter value than existing  Conductivity Dumping valve will OFF check on the display which show fault  “PROCESS OK”
12 W.F.I TEPERATURE HIGH
  Decrease the cooling water flow rate & wait till the W.F.I out temperature is become higher than the set value Check on display which will show “W.F.I. TEMP. HIGH“
Increase the cooling water flow rate & wait till the W.F.I water out temperature is become lower than the set value Check on display which will show  “PROCESS OK”
13 W.F.I TEMPERATURE LOW
  Increase the cooling water flow rate & Decrease Feed water flow rate; wait till the W.F.I out temperature is become lower than the set value. Check on display which will show “W.F.I. TEMP. LOW” dumping valve & air vent valve will get ON and cooling pump will stop.

 

Decrease the cooling water flow rate & Increase Feed water flow rate wait till the W.F.I out temperature is become higher than the set value. Check on display which will show  “PROCESS OK” dumping valve & air vent valve will get OFF and cooling pump will on.
14 COOLING WATER TEMPERATURE HIGH
  Decrease the cooling water flow rate & wait till the cooling water out temperature is become higher than the set value. Check on display which will show “C.W. TEMP. HIGH”  
Increase the cooling water flow rate & wait till the cooling water out temperature is become lower than the set value. Check on display which will show  “PROCESS OK”  
15 FEED PUMP OVER LOAD
  While pump is running give link bet’n 24VDC and Feed Pump O/L. Immediately Feed pump will stops automatically Check the fault on Display “FEED PUMP O/L  “.
Now Again remove link bet’n them. As soon as contact of relay gets change over Feed pump will start automatically check the Display which shows the “PROCESS OK”.  

 

16 COOLING PUMP OVER LOAD
  While pump is running give link bet’n 24VDC and Cooling Pump O/L. Immediately Cooling pump will stop automatically Check the fault on Display “COOLING PUMP O/L “.  
Now Again remove link bet’n them. As soon as contact of relay get change over Cooling pump will start automatically check the Display which shows the  “PROCESS OK”.  
17 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.  
18 INSUFFICIENT COOLING WATER
  Turn pressure setting knob clock-wise to set pressure more than actual pressure. Check the display which show fault “INSUFF. COOLING WATER”  
Turn pressure setting knob Anti-clock-wise to set pressure less than actual pressure Check the display which shows “PROCESS OK “  
19 FEED WATER DISCHARGE PRESSURE LOW  
  Turn pressure setting knob clock-wise to set pressure more than actual pressure, Check the display which show fault “F. W. PRESSURE LOW”.  
  Turn pressure setting knob Anti-clock-wise to set pressure less than actual pressure Check the display which shows “PROCESS OK “.  
  INTERLOCKING
A FEED PUMP Emergency Stop
Air Pressure Low
Boiler steam temperature low

(After 5 minutes feed pump will stop)

Conductivity Of Feed Water High  
Insufficient Evaporation  
Initial heating time.  
Insufficient feed water  
Distill Water Level High  
Purging On Problem  
Purging Off Problem  
Feed pump Over load  
B COOLING PUMP Cooling pump overload  
Low W.F.I  temperature  
Emergency Stop  
Air Pressure Low  
Insufficient cooling water  
C DUMPING VALVE Initial drain time
Low Boiler steam temperature
Low W.F.I. temperature
Conductivity of W.F.I high
Emergency Stop
Air Pressure Low
D AIR VENT VALVE When the W.F.I. temperature low than the set value Air Vent Valve will ON.
Air vent valve will operate automatically as per timer set in parameter. It will operate for set time at set interval.
E PURGING VALVE Last column level high
Purging hold time
Shut down Timer after Process Stop
G INTER LOCKING FOR CHILLED WATER IN VALVE (PNA3) Emergency stop
    Air Pressure Low

 

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 which are installed on the plant as per approved DR.
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    
  • SUMMARY REPORT
  • Summary of  the results obtained during OQ:  
  • Significant deviations observed during OQ:
  • Conclusions:

 

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