Installation qualification for pure steam generator

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

ObjectiveTo check the documents required for the job as per the checklist.
Material Documents list submitted in the FAT.
MethodThe 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 CriteriaThe documents submitted shall be as specified in the list of reference documents.

LIST OF REFERENCE DOCUMENTS

Title Of DocumentSubmittal StageDocument No.
List of the reference drawingsSAT
Material history chart with Test CertificatesSAT
Bought–out componentsSAT
Components certification & calibration.SAT
Dimensional reportSAT
Surface finish reportSAT

 LIST OF REFERENCE DRAWINGS

ObjectiveTo check the reference drawing required for a job against the list mentioned 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 drawings.

 

Title Of DrawingSubmittal StageDrawing No.
 G.A. DrawingSAT
P & I DiagramSAT
Wiring diagramSAT
Pneumatic DiagramSAT
Operation Logic DiagramSAT

 MATERIAL HISTORY CHART

ObjectiveTo prove that the materials used for the 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 to the vendor, by the vendor
Acceptance criteriaThe certificates shall prove that the materials used for the construction of components are as per the approved specifications.

MATERIAL HISTORY CHART

Part Description & SizeAcceptance Criteria
MaterialCertificate 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”X1.65mmASME BPE 316L
Purified water in and out line:0.5” X1.65mmASME BPE 316L
Preheater assembly to condenser sensor bowl line:1” X1.65mmASME BPE 316L
Steam line: 1.5” NB X SCH 10AISI 304
 
MINI TC GasketSILICON
1/2” T/C GasketSILICON
1” T/C GasketSILICON
2” T/C GasketSILICON
3” T/C GasketSILICON

 BOUGHT–OUT COMPONENTS

ObjectiveTo prove that the bought-out components used for the construction of the equipment are as per the approved specifications.
MaterialBought Out components specification sheets (From the original manufacturer)
MethodInspect the installed component. Compare the 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 the construction of the equipment is as per the approved specifications.

BOUGHT OUT COMPONENTS

ComponentMakeCertificate Type
MECHANICAL COMPONENTS
Feed Pump for feed waterGrundfosTest Certificate
Flow  indicatorKrohne MarshallTest Certificate
Non Return valveAlfa LavalTest Certificate
Pneumatic  valveGemuCompliance Certificate
Sampling valveCrane ProcessTest Certificate
Diaphragm valveCrane ProcessTest Certificate
Steam TrapSpiraxTest Certificate
Safety valveSpiraxTest Certificate
Pressure Gauge for Pure SteamWaareeCalibration Certificate
Pressure Gauge for Boiler steamWaareeCalibration Certificate
Pressure Gauge for FeedwaterWaareeCalibration Certificate
Ball ValveShaktiTest Certificate
Air  Pressure RegulatorFestoTest Certificate
Globe ValveShaktiTest Certificate
Vent FilterPallTest Certificate
Needle ValveShaktiTest Certificate–
ELECTRICAL COMPONENTS
PLCAllen BradleyTest Certificate
DisplayAllen BradleyTest Certificate
Conductivity meterYokogawaCalibration Certificate
Conductivity sensorYokogawaCalibration Certificate
Temperature SensorRadixCalibration Certificate
Pressure switchOrionTest Certificate
Liquid level sensor on NCGRPune TechtrolTest Certificate
Liquid level Sensor at ColumnE+HCalibration Certificate
Pressure TransmiterJumoComplience Certificate
Temperature TransmitterRadixCalibration Certificate

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 a certified calibration laboratory)
MethodThe 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 criteriaThe verification shall prove that the designated components used for the construction of the equipment are properly tested/calibrated.

COMPONENTS CERTIFICATION & CALIBRATION

ComponentMakeCertificate 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 MeterYokogawa
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 LineRadix
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

ObjectiveDimension check against Approved GA Drawings.
  InstrumentsMeasure Tape 0-3000mm, Vernier Caliper 0- 300 mm,
MethodDirect 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 CriteriaAll 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

ParameterValue 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 PSG1.5 ” ASA 150 # Flange
Compressed air inlet½” BSP FEMALE THD.
Header Drain1.5” BSP FEMALE THD.
Drain Header Air Vent1” BSP FEMALE THD.
Pure steam outlet2” TRICLOVER
Feed water Inlet1” TRICLOVER

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.

 PLC INPUT OUTPUT CHECK

ObjectiveTo check the Input Output and to verify against the wiring diagram requirement.
MethodCheck the input-output against the 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 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:

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