Installation qualification for pure steam generator
To confirm, by physical inspection and testing, that the fabrication and assembly of the equipment and any auxiliary support systems, conform to the Design parameters as per the Design Review.
SCOPE
The tests shall be carried out at the customer’s place.
The verification of compliance to specifications as per vendor 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.
RESPONSIBILITIES
Inspection
Customer or their authorized representatives are responsible for this IQ document
All documents shall be checked and approved by the customer or their authorized representatives.
Production personnel will perform this test.
CHECK POINTS & TESTING
| Objective | To check the documents required for the job as per the checklist. |
| Material | Documents list submitted in the FAT. |
| Method | The submitted documents shall be checked for correct Document 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
| Title Of Document | Submittal Stage | Document No. |
| List of the reference drawings | SAT | |
| Material history chart with Test Certificates | SAT | |
| Bought–out components | SAT | |
| Components certification & calibration. | SAT | |
| Dimensional report | SAT | |
| Surface finish report | SAT |
LIST OF REFERENCE DRAWINGS
| Objective | To check the reference drawing required for a job against the list mentioned 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 drawings. |
| Title Of Drawing | Submittal Stage | Drawing No. |
| G.A. Drawing | SAT | |
| P & I Diagram | SAT | |
| Wiring diagram | SAT | |
| Pneumatic Diagram | SAT | |
| Operation Logic Diagram | SAT |
MATERIAL HISTORY CHART
| Objective | To prove that the materials used for the 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 to the vendor, by the vendor |
| Acceptance criteria | The certificates shall prove that the materials used for the construction of components are as per the approved specifications. |
MATERIAL HISTORY CHART
| Part Description & Size | Acceptance Criteria | |
| Material | Certificate No. | |
| Column Shell
14 SWG Sheet |
ASTM A240M
GR316L |
|
| Condenser Shell
14 SWG Sheet |
ASTM A240M
GR316L |
|
| Condenser Tubes
12.7 MM OD X 1 MM Thk. Tube |
SA213 TP316L | |
| Preheater Shell
3” OD X 16 SWG Pipe |
AISI 304 | |
| Preheater Tubes
12.7 MM OD X 1 MM Thk. Tube |
SA213 TP316L | |
| Sampling Pre heater Shell
3” OD X 16 SWG Pipe |
AISI 304 | |
| Sampling Preheater Tubes
¾” OD X 16 SWG Pipe |
SA 249 TP 316L | |
| Separator Fabrication
20 SWG SHEET |
ASTM A240M
GR316L |
|
| Pure steam Outlet :
2” X 1.65mm Pipe |
ASME BPE 316L | |
| Pure Steam Sampling line
0.5” X 1.65 mm Thk. Tube |
ASME BPE 316L | |
| Interconnecting pipe line& WFI outlet line:0.5”X1.65mm | ASME BPE 316L | |
| Purified water in and out line:0.5” X1.65mm | ASME BPE 316L | |
| Preheater assembly to condenser sensor bowl line:1” X1.65mm | ASME BPE 316L | |
| Steam line: 1.5” NB X SCH 10 | AISI 304 | |
| MINI TC Gasket | SILICON | |
| 1/2” T/C Gasket | SILICON | |
| 1” T/C Gasket | SILICON | |
| 2” T/C Gasket | SILICON | |
| 3” T/C Gasket | SILICON | |
BOUGHT–OUT COMPONENTS
| Objective | To prove that the bought-out components used for the 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 the 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 the construction of the equipment is as per the approved specifications. |
BOUGHT OUT COMPONENTS
| Component | Make | Certificate Type |
| MECHANICAL COMPONENTS | ||
| Feed Pump for feed water | Grundfos | Test Certificate |
| Flow indicator | Krohne Marshall | Test Certificate |
| Non Return valve | Alfa Laval | Test Certificate |
| Pneumatic valve | Gemu | Compliance Certificate |
| Sampling valve | Crane Process | Test Certificate |
| Diaphragm valve | Crane Process | Test Certificate |
| Steam Trap | Spirax | Test Certificate |
| Safety valve | Spirax | Test Certificate |
| Pressure Gauge for Pure Steam | Waaree | Calibration Certificate |
| Pressure Gauge for Boiler steam | Waaree | Calibration Certificate |
| Pressure Gauge for Feedwater | Waaree | Calibration Certificate |
| Ball Valve | Shakti | Test Certificate |
| Air Pressure Regulator | Festo | Test Certificate |
| Globe Valve | Shakti | Test Certificate |
| Vent Filter | Pall | Test Certificate |
| Needle Valve | Shakti | Test Certificate– |
| ELECTRICAL COMPONENTS | ||
| PLC | Allen Bradley | Test Certificate |
| Display | Allen Bradley | Test Certificate |
| Conductivity meter | Yokogawa | Calibration Certificate |
| Conductivity sensor | Yokogawa | Calibration Certificate |
| Temperature Sensor | Radix | Calibration Certificate |
| Pressure switch | Orion | Test Certificate |
| Liquid level sensor on NCGR | Pune Techtrol | Test Certificate |
| Liquid level Sensor at Column | E+H | Calibration Certificate |
| Pressure Transmiter | Jumo | Complience Certificate |
| Temperature Transmitter | Radix | Calibration Certificate |
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 a certified calibration laboratory) |
| Method | The Vendor shall present Test certificates and Calibration certificates of the designated components (From the original manufacturer or 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 the construction of the equipment are properly tested/calibrated. |
COMPONENTS CERTIFICATION & CALIBRATION
| Component | Make | Certificate No. | |
| MECHANICAL COMPONENTS | |||
| Feed Pump(CRN 3 -12)At the inlet of the feed water to PSG (MP1) | Grundfos | ||
| Variable area indicator(KM25-P)100 – 1000 LPHAt discharge side of Feed pump (FI1) | Krohne Marshall | ||
| Pneumatic valve (DN 15 )At column purging water line (PNA1) | Gemu | ||
| Pneumatic valve (DN 15 / DN 20) At discharge of Feed Pump (PND3) | Gemu | ||
| Pneumatic Valve (DN 15) At Feed Water In gas cooler (PND1) | Gemu | ||
| Globe valve At the inlet of the plant steam (GV1) | Shakti | ||
| Non-return valve (DN 25 )At Pure Steam Sampling Line (NRV1) | Alfa Laval | ||
| Non-return valve (DN 25) At vacuum break line of GRC (NRV2) | Alfa Laval | ||
| Diaphragm valve (DN 15 ) At Feed Water Inlet to PSG Line (DP1) | Gemu | ||
| Diaphragm valve (DN 15 )At feed water inlet (DP2) | Gemu | ||
| Air regulator At the Inlet of the compressed air (APR1) | Festo | ||
| Steam Trap BPT-21,15 NB At First column air vent line (ST2) | Spirax | ||
| Steam Trap BPT-21,15 NB At Plant Steam Condensate Drain of PH1(ST3) | Spirax | ||
| Steam Trap FT-14CI-10 (c), 15 NB At Boiler Steam Condensate line of first condenser (ST1) | Spirax | ||
| Safety valve SV11 75-125 PSI At inlet of the plant steam line (SV1) | Spirax | ||
| Pressure Gauge (0-16 Kg/cm2 )At plant steam line (PG1) | Waaree | ||
| Pressure Gauge (0-16 Kg/cm2 )At discharge side of feed pump (PG2) | Waaree | ||
| Pressure Gauge( 0-7 Kg/Cm2 )At pure steam line (PG3) | Waaree | ||
| Manual ball valve ½”At plant steam condensate drain through steam trap (BV2) | Shakti | ||
| Manual ball valve ½”At plant steam condensate drain bypass to steam trap (BV1) | Shakti | ||
| Manual ball-valve ½”At the steam inlet to preheater (BV3) | Shakti | ||
| 2 Way Pneumatic valve “NO” Type( DN 15) For gas removal column drain (PNANO) | Gemu | ||
| Pneumatic Valve (DN 15) At gas removal column to gas cooler (PNA2) | Gemu | ||
| Disposable Vacuum break Filter (KA1PFRP1 )At top of GRC (VF1) | Pall | ||
| Plate-type Heat Exchanger For drain cooling (PHE1) | Swep International | ||
| Manual ball-valve (½”)At the pure steam sample-taking line (BV4) | Shakti | ||
| Pneumatic ValveDN 25At the cooling water of heat exchanger PNA3) | Burket | ||
| Needle valve ½” At the sampling preheater line for conductivity (NV1) | Shakti | ||
| Diaphragm valve( DN 25) At the sample taking line (DP3) | Gemu | ||
| ELECTRICAL COMPONENTS | |||
| PLC:
|
1762IR4
1766LX32BA |
Allen Bradley | |
| DISPLAY: | Allen Bradley | ||
| Conductivity Meter | Yokogawa | ||
| Conductivity sensor At the inlet of the machine (CS1) | Yokogawa | ||
| Conductivity Sensor At Pure Steam Condensate Sampling Point (CS2) | Yokogawa | ||
| Temperature sensor (-50 to 200o C) Boiler steam line (TS1) | Radix | ||
| Temperature sensor (-50 to 200o C) Pure Steam Line (TS2) | Radix | ||
| Temperature sensor (-50 to 200o C) Pure Steam Line | Radix | ||
| Pressure Transmitter( -1 to 5 Bar G )Pure Steam Line (PT1) | Jumo | ||
| Pressure Switch (0.5 -7.0 Bar) At air pressure Line (PS1) | Orion | ||
| Pressure Switch (0.5 -7.0 Bar) Pure steam Line (PS2) | Orion | ||
| Pressure Switch (0.2-2.6Bar) at the inlet side of feed water (PS3) | Orion | ||
| Pressure Switch (1-15 Bar) For GRC to PH2 (PS4) | Orion | ||
| Liquid Level Sensor (FLT-20H )On column (LS1) | E+H | ||
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 and connection Points.
Install the plant in a 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 DIMENSIONS:
DIMENSION CHECKS
CHECK DIMENSION AGAINST GA DRAWING.
DIMENSIONAL MEASUREMENTS
| Parameter | Value from Drawing (mm) | Actual Value (mm) |
| Overall height H | ||
| Overall Width W | ||
| Overall Depth D | ||
| Pure Steam Outlet Height |
UTILITY CONNECTION POINTS CHECKS
| Boiler Steam to PSG | 1.5 ” ASA 150 # Flange |
| Compressed air inlet | ½” BSP FEMALE THD. |
| Header Drain | 1.5” BSP FEMALE THD. |
| Drain Header Air Vent | 1” BSP FEMALE THD. |
| Pure steam outlet | 2” TRICLOVER |
| Feed water Inlet | 1” TRICLOVER |
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. |
PLC INPUT OUTPUT CHECK
| Objective | To check the Input Output and to verify against the wiring diagram requirement. |
| Method | Check the input-output against the 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 | ( PASS/ FAIL) |
| Check the input-output against the wiring diagram visually during operation. | All the Input and output shall meet the requirements. |
SUMMARY REPORT
- Summary of the results obtained during IQ:
- Significant deviations observed during IQ: