Water generation system Operational qualification
The purpose of Operational Qualification is to establish confidence that the Purified Water Generation System is capable of operating within these established limits and tolerances with the following features but not limited to:
The functional design specification addresses the permanent recording, visual indication, design/specification range, normal operating range, alert and alarm limits, and the functional interrelationship of each component within the system. All of these requirements are to be verified during the OQ phase to ensure that they operate as planned and that the requirements have been anticipated correctly.
The OQ is performed on systems, which may consist of facilities, utilities, and/or equipment; to verify operation within specified parameters. Execution of the OQ involves testing parameters that regulate the process or product quality. Verification of proper operation of controllers, indicators, recorders, alarms, and interlocks, is performed and documented during the OQ testing.
This is the policy that a written protocol will be followed for the process of testing to ensure that the Purified Water Generation System and its components operate as specified and within the anticipated range.
Why:
This document is to verify that all aspects of the Purified Water Generation System operate as intended throughout all anticipated ranges. This document also defined the process of testing to ensure that individual components and systems operate as specified, and how that information is recorded.
What:
- To demonstrate that the Purified Water Generation System performs reproducibly and consistently.
- To document performance of the Purified Water Generation System for future
- To assure that Purified Water Generation System is adequate to support for which system is intended.
- To develop the SOP’s for start-up, operation, shut down and sanitisation of the Purified Water Generation System.
- To document test procedures and criteria for acceptance.
- To define parameters that should be reproducible.
- To verify performance across full range of operation from minimal to maximal load, with special evaluation at upper and lower limits.
When:
This procedure will be followed after the completion of installation qualification of Purified Water Generation System in the company. This document will also be followed at the time of installation or removal of any part in the existing Purified Water Generation System (RO-EDI) by following the change control management.
Re-qualification:
- Operational Qualification to be re-qualified on:
- Any major modification in the existing Purified Water Generation System since purchase, which can affect the quality of the product.
- If there is a change in the location of the Purified Water Generation System.
Responsibility:
The team for the Operational Qualification shall be comprised of the head of the following functional area. The exact representation of each department has been stated in validation project responsibility matrix.
- Engineering
- Quality Assurance
- Head Operations
- Head Quality
The members of the project validation team, Representative of Manufacturer and Representative of Supplier, their responsibilities will be as follows:
| Functional Area | Responsibilities |
| Vendor | -Pre-review/approval of Operational Qualification Report -Review / Approval of Final Operational Qualification Report-Review / Approval of change control procedure-Co-ordination / execution in testing |
| Engineering | -Pre-review/approval of Operational Qualification Report -Review / Approval of Final Operational Qualification Report -Co-ordination for engineering activity and to provide all utilities Required for operation. -Co-ordination & execution of internal and external calibration Program. |
| Quality Assurance | -Draft / Approval of Operational Qualification Report -Review / Approval of Final Operational Qualification Report -Review and Approval of Change control if any and its impact on the quality of the product. -Co-ordination & execution of Internal and External calibration Program. |
| Head Operations | -Pre review/approval of Operational Qualification Report -Review / Approval of Final Operational Qualification Report |
| Head Quality | -Pre-review / approval of Operational Qualification Report -Review / Approval of Final Operational Qualification Report |
(Note: Ensure that the rise of temperature during sanitization should not be more than 30 C per minute.)
- Carry out the Hot water sanitization of system at 80-850 C temperature.
- Start the sanitization of Loop in auto mode.
- Connect the RO II & EDI system with CIP system with flexible hose
RO-EDI SYSTEM
Sanitization is done when microbial growth occurs in RO & EDI System. Frequency of sanitization will be decided by QA department after 3 seasonal validation of the plant. In normal case frequency of sanitization is 15 days or month.
WHEN? –Sanitization is done to remove microbial growth from the system.
SANITIZATION PROCEDURE:
The water generated from the outlet of EDI will be as per USP 34 Standards for Purified Water.
The Permeate water from the RO system will be fed to the Electro Deionization Unit (EDI) having designed capacity of 2000 LPH. The EDI system has a recovery of 90%.
The Reverse Osmosis System consists of thin film composite type Reverse Osmosis membrane of DOW. The material of construction of the RO membrane is Polyamide. The RO membrane is housed in the High Pressure SS 316L Wettable Parts Housing having TC end connection.
The outlet water of RO pass one is feed to RO pass two system. The Second pass Reverse Osmosis System will generate 2200 liters/hr of water with an overall recovery of 80%. The generated water will have total dissolved solids less than 15-20 ppm.
The Reverse Osmosis System consists of thin film composite type Reverse Osmosis membrane of DOW. The material of construction of the RO membrane is Polyamide. The RO membrane is housed in the High Pressure SS 316L Wettable Parts Housing having TC end connection.
This soft water is then fed to the Reverse Osmosis First pass System by means of a High Pressure Vertical multistage Pump with SS 304 wettable parts. The First pass Reverse Osmosis System will generate 2700 liters/hr water with an overall recovery of 70 %. The generated water will have total dissolved solids less than 150 ppm. The semi-permeable reverse osmosis membrane has molecular weight cut off less than 150 MWCO. The Reveres Osmosis membrane acts as positive barrier to remove dissolved solids, organic compounds & bacteria.
ORP Analyzer is provided so as to check the absence/presence of chlorine in the feed water to the RO System. If free chlorine is sensed in the feed water it will give an indication on the panel & open the dumping valve and dump the high ORP water for 300 secs. & Even if the ORP value is not below the set point it will trip the system.
pH Correction Dosing System is provided to adjust the feed pH of RO feed water as 6.5 – 8.5. The treated water is then passed through 5 micron Cartridge Filter to trap the suspended solids. This will avoid chocking of RO membranes due to suspended solids.
Antiscalent Dosing System is then dosed in the soft water to avoid scale formation on the RO Membranes.
Sodium Metabisulphite (Na2S2O5) is then dosed in the chlorinated water to neutralize the free chlorine (excess chlorine) present in the filtered water.
Soft Water after Softener unit is fed to Purified Water Generation System.
.SYSTEM DESCRIPTION:
POST-TREATMENT:
Hot Water Sanitizable Electro – Deionization Unit
Conductivity meter with Alarm
SYSTEM DESCRIPTION
The Fully Automated PLC based Purified Water Generation system generates 2.0 m3/hr. of Purified water as Per current USP.
SCHEME:
FIRST PASS REVERSE OSMOSIS (HOT WATER SANITISABLE) SYSTEM:
- SMBS Dosing System
- Antiscalant Dosing System
- pH Correction System
- 5 – Micron Cartridge Filter
- ORP Analyzer and pH sensor along with auto Dumping Valve
- RO High-Pressure Pump
- Reverse Osmosis Membranes along with High-Pressure Housing
- Conductivity Meter with Alarm
SECOND PASS REVERSE OSMOSIS (HOT WATER SANITISABLE) SYSTEM:
- RO High-Pressure Pumps
- Reverse Osmosis Membranes along with High-Pressure Housings
- Conductivity meter with Alarm
- Circulate the hot water for 1 hr after the temperature reaches 850
- After 1 hr. of recirculation stop the heater & allow the temp in the system to come down gradually.
- After the temperature reaches 50-570 C, stop the system & drain the CIP tank water through the tank drain valve.
SOP VERIFICATION:-
| Observation | Observation – Yes / No |
| Most current revisions in use | |
| Operating personnel understand and follow SOP descriptions and requirements. | |
| SOP provides adequate direction |
PURPOSE:
KEY FUNCTIONALITY
The purpose of this procedure is to demonstrate that the control panel of the Purified Water Generation System provides the proper functionality as specified by the manufacturer.
TESTING:
Check that all the displays on the panel are properly Labeled / Identified.
Turn on the power from the electrical panel.
Set the control(s) on the panel.
Verify functionality of each component on the panel against its Specified functions. Observe and record the responses of the control panel.
KEY FUNCTIONALITY
Name Equipment: Purified Water Generation system
Equipment Make :
Location : Purified Water Generation Plant Room
PANEL: FOR PURIFIED WATER GENERATION PLANT OPERATION
| Key / Switch Description | Specified Function | Matches with Specified Function (Yes / No) |
| ON / OFF for RO High Pressure Pump – I | To start and stop the RO High-Pressure Pump-I in manual mode | |
| ON / OFF for RO High Pressure Pump – II | To start and stop the RO High-Pressure Pump-II in manual mode | |
| ON / OFF for EDI. | To start and stop the EDI in manual mode. | |
| ON / OFF for CIP Feed Pump | To start and stop the CIP Feed Pump in manual mode. | |
| ON / OFF for CIP Heater | To start and stop the CIP Heater in manual mode. | |
| Auto–Manual Switch for RO-EDI System | The two-way switch is provided for change over from Auto to Manual operation for the RO-EDI System. | |
| Accept | To accept the alarm and hooter stop. | |
| Emergency Stop | To stop the system immediately. |
DISPLAY FUNCTIONALITY
Name Equipment: Purified Water Generation System
Equipment Make :
Location : Purified Water Generation Plant Room
PANEL: FOR PURIFIED WATER GENERATION PLANT OPERATION
| Key Indicator | Specified Function | Matches with Specified Function (Yes / No) |
| Indication Lamp provided for three phases (R, Y & B) | To indicate the condition/status of the three phases of power. | |
| Indication Lamp provided for ON / OFF/ TRIP of RO High Pressure Pump I | To indicate the condition/status of the RO High-Pressure pump I in auto as well as manual mode. | |
| Indication Lamp provided for ON / OFF/ TRIP of RO High-Pressure Pump II | To indicate the condition/status of the RO High-Pressure pump II in auto as well as manual mode. | |
| Indication Lamp provided for ON / OFF/ TRIP of EDI. | To indicate the condition/status of EDI in auto as well as manual mode. | |
| Indication Lamp provided for ON / OFF / TRIP of CIP Feed Pump | To indicate the condition / Status of CIP Feed Pump in auto as well as manual mode. | |
| Indication Lamp provided for ON / OFF of CIP Heater | To indicate the condition / Status of CIP Heater in auto as well as manual mode. | |
| Digital DC Voltmeter for EDI. | To display the applied DC voltage across the EDI electrodes. | |
| Digital DC Ammeter for EDI. | To display the DC drawn by the EDI unit. | |
| RO Output Conductivity | To display the conductivity at the outlet of the RO. | |
| MMI | To indicate an overview of the plant and display interlocking and faults of the plant. |
INITIAL SET POINTS:
| Instruments | Initial SetPoint | Actual Set Point |
| Rotameter at the inlet of RO System | ||
| Rota meter at Reject line Of RO-I System | ||
| Low-pressure switch at the inlet of ROHP-I | ||
| High Pressure Switch at outlet of ROHP-I (HPS-001) | ||
| ORP value at the inlet of RO System | ||
| Conductivity Meter at the outlet of RO-I System | ||
| Rota meter at Reject line Of RO-II System | ||
| Low-pressure switch at the inlet of ROHP-II | ||
| High Pressure Switch at outlet of ROHP-II (HPS-002) | ||
| Conductivity Meter at the outlet of RO-II System | ||
| Rota meter at Feed line Of EDI (RM-07) | ||
| Rota meter at Conc. line Of EDI (RM-08) | ||
| Low-Pressure Switch at the inlet of EDI(LPS-003) | ||
| Conductivity at the outlet of EDI (CIC-03) |
CRITICAL VARIABLES TO BE MET:
PURIFIED WATER GENERATION SYSTEM (TWO PASS RO-EDI)
| Test Function: Sodium Metabisulphite(SMBS-01) Dosing Tank Low Level Switch Procedure: Operate the Purified Water Generation system by following the Standard Operating Procedure for operation of the Purified Water Generation system. Pull the low-level switch from the SMBS dosing tank. After an operation record the response. | |
| Response: | |
| Acceptance criteria: Should give an alarm “LOW LEVEL IN SMBS TANK” and after some time if the condition remains the same Should Trip the Plant with Hooter and indicate on the panel –“LOW LEVEL IN SMBS TANK PLANT TRIP” ( Note: To be checked in Normal Auto mode / Auto flushing Mode) |
| Test Function: Anti-Scaling Dosing Tank Low-Level Switch Procedure: Operate the Purified Water Generation system by following the Standard Operating Procedure for the operation of the Purified Water Generation system. Pull the low-level switch from the Scalant dosing tank.After an operation record the response. | |
| Response: | |
| Acceptance criteria: Should give an alarm “LOW LEVEL IN ADS TANK” and after some time if the condition remains the same Should Trip the Plant with Hooter and indicate on the panel –“LOW LEVEL IN ADS TANK PLANT TRIP” ( Note: To be checked in Normal Auto mode/ Auto flushing Mode ) |
| Test Function: pH Correction Dosing Tank Low-Level Switch Procedure: Operate the Purified Water Generation system by following the Standard Operating Procedure for operation of the Purified Water Generation system. Pull the low-level switch from the pH Correction dosing tank.After an operation record the response. | |
| Response: | |
| Acceptance criteria: Should give an alarm “LOW LVL IN pHC TANK” and after some time if the condition remains the same Should Trip the Plant with Hooter and indicate on the panel “LOW LVL IN pHC TANK PLANT TRIP” ( Note : To be checked in Normal Auto mode/ Auto flushing Mode ) |
| Test Function: ORP Sensor, Transmitter & Controller: Procedure: Operate the Purified Water Generation system by following the SOP for the operation of the Purified Water Generation system. Stop the SMBS dosing pump and allow the high-free chlorine water to pass through Case I: Restart the SMBS dosing pump after 1 min. Case II: Not to start SMBS dosing pump for 5 mins. Allow to pass chlorinated water (less than 0.5 ppm free chlorine) through the ORP analyzer and check the response of the sensor. (Note: To be checked in Normal Auto mode / Autoflushing Mode / PLC Manual Mode.) | |
| Response: | |
| Acceptance criteria: Case I: After getting a response more than set value the control valve AV-02 should open up & the chlorinated water should be dumped. If the ORP value comes within the limit it should close the AV-02 after 30 sec. of consistent low reading. (“HIGH ORP “) OR Case II: If the ORP value is high for more than 5 min. It should trip the plant with an alarm & indication on MMI. (“VERY HIGH ORP “) |
| Test Function: Reverse Osmosis System (Pass – I) Procedure: Operate the Purified Water Generation system as per the SOP for the operation of the Purified Water Generation System. Check and record the conductivity of RO Pass – I water on the Conductivity indicator provided on the panel and simultaneously take the sample for QC analysis and check the conductivity. After an operation record the response. | |
| Response: | |
| Acceptance criteria: Permeate Water should be clear & colorless, conductivity should be less than 150 µs/cm & the reject flow rate should be 1.1 m3/hr, and the Feed Flow rate at 3.8 m3/hr , (Note: To be checked in Normal Auto mode.) |
| Test Function: Reverse Osmosis System (Pass – II) Procedure: Operate the Purified Water Generation system as per the SOP for the operation of the Purified Water Generation System. Check and record the conductivity of RO Pass – II water on the Conductivity indicator provided on the panel and simultaneously take the sample for QC analysis and check the conductivity. After an operation record the response. | |
| Response: | |
| Acceptance criteria: Permeate Water should be clear & colorless, conductivity should be less than 20µs/cm & the reject flow rate should be 0.5 m3/hr, and the Feed Flow rate at 2.7 m3/hr,(Note: To be checked in Normal Auto mode.) |
| Test Function: Reverse Osmosis System: High-pressure Switch (HPS-001) Procedure: Operate the Purified Water Generation System as per the operating procedure for Operation of the Purified Water Generation System. Reset the High-Pressure Switch value in the operating condition below the operating feed pressure of the RO system. Perform this challenging test of the pressure switch. After an operation record the response. | |
| Response: | |
| Acceptance criteria: The plant should trip with an alarm & indication on the panel. “HPS AT ROHP-I” (Note: To be checked in Normal Auto mode/ Auto flushing Mode) |
| Test Function: Reverse Osmosis System: High-pressure Switch (HPS-002) Procedure: Operate the Purified Water Generation System as per the operating procedure for Operation of the Purified Water Generation System. Reset the High-Pressure Switch value in the operating condition below the operating feed pressure of the RO system. Perform this challenging test of the pressure switch. After an operation record the response | |
| Response: | |
| Acceptance criteria: The plant should trip with an alarm & indication on the panel. “HPS AT ROHP-II” (Note: To be checked in Normal Auto mode/ Auto flushing Mode) |
| Test Function: RO: Conductivity sensor (CIC-01) & Control Valve (AV-04) Procedure: Operate the Purified Water Generation System as per the operating procedure for the Operation of the Purified Water Generation System. Reset the conductivity set point below the actual operating value. Case I: Bring it to the normal set point after 1 min. up to 4 mins. Case II: Allow the set point below the actual reading for more than 5 minutes. After an operation record the response | |
| Response: | |
| Acceptance criteria: Case I: The Dumping Valve AV-04 should open immediately & dump the permeate water. The CIC-01 High should be indicated on the panel. (“HIGH COND AT RO 01”) After the conductivity value is changed to the original pre-set value After 30 secs. of consistently low value above the set point the control value AV-04 automatically closes & system starts automatically. Case II: After 5 minutes of consistent dumping it will trip the system with an alarm and indication on the panel. (“VERY HIGH COND AT RO 01”) (Note: To be checked in Normal Auto mode/ Auto flushing Mode) |
| Test Function: RO: Conductivity sensor (CIC-02) & Control Valve (AV-06) Procedure: Operate the Purified Water Generation System as per the operating procedure for the Operation of the Purified Water Generation System. Reset the conductivity set point below the actual operating value. Case I: Bring it to the normal set point after 1 min. up to 4 mins. Case II: Allow the set point below the actual reading for more than 5 minutes. After an operation record the response. | |
| Response: |
| Test Function: Electro-Deionization Unit: Conductivity Sensor (CIC-03) & Flow Diverter Valve (FDV 01) Procedure: Operate the Purified Water Generation System as per the operating procedure for the Operation of the Purified Water Generation System. Reset the conductivity set point below the actual operating value. Case I: Bring it to the normal set point after 1 min. up to 4 min. Case II: Allow the set point below the actual reading for more than 5 minutes. After an operation record the response | |
| Response: | |
| Acceptance criteria: Case I: The dumping valve – FDV should open immediately & dump the EDI outlet water. The CIC-03 High should be indicated on the panel. After the conductivity value is changed to the original preset value After 30 secs of consistent low value below the set point the flow diverter valve – FDV 01 will automatically close & EDI starts automatically. (“HIGH COND AT EDI OUTLET”) Case II: After 5 mins of consistent dumping it will trip the system with alarm and indication on the panel. (“VERY HIGH COND AT EDI OUTLET”) (Note: To be checked in Normal Auto mode) |
| Test Function: Emergency Stop Procedure: Press Emergency Stop on the main control panel during normal operation. Note the alarm is generated and the message is displayed on MMI when Emergency Stop is pressed. Release the Emergency stop button. Switch ON the control power and reset the system by pressing the reset button on the MMI | |
| Response: | |
| Acceptance criteria: The e-stop button shall be locked upon pressing. The Purified Water Generation System should stop operation immediately. An audio-visual Alarm shall be generated. “EMERGENCY PRESSED” |
FEED LIMITING FACTOR FOR RAW WATER:
Raw water will be analyzed for a minimum of three consecutive days for chemical and microbiological and based on the results feed limiting factor for raw water will be established. The final feed limiting factor for raw water will be established only after three days of validation.
LIMIT FOR RAW WATER CHEMICAL ANALYSIS
| Test | Limit |
| Colour | < 5 CTU |
| Ph | 7.5 |
| SDI | 900 |
| Total Dissolved Solids | 1.8 |
| Total Alkalinity | Not check |
| Total Suspended Solids | 750 ppm |
| Total Hardness | 120 ppm |
| Calcium as CaCO3 | 300 ppm |
| Magnesium as CaCO3 | 100 ppm |
| Sulphate as SO4 | 200 ppm |
| Nitrates as NO3 | 36.11 ppm |
| Chlorides as Cl | 0.975ppm |
| Silica as SiO2 | 43.68 ppm |
| Colloidal Silica | 2.3 ppm |
| Reactive Silica | 92.3 ppm |
| Total Chloride as CaCO3 | 0.7 ppm |
| Sulphate as CaCO3 | 5.6 ppm |
| TOC | 5.6 ppm |
| TVC | 1000 ppb |
MICROBIOLOGICAL MONITORING OF RO-EDI PLANT:
Samples from the different sampling points of RO-EDI Plant shall be tested for Total Aerobic Microbial Count and Absence of Pathogens namely coliforms including E. coli and Pseudomonas aeruginosa, Salmonella, Staphylococcus aureus for a minimum of seven days consecutive days and only after getting results within limit Purified water generation system can be taken into operation.
The microbiological tests will be carried out as per the standard operating procedures
Acceptance Criteria for Pre-Treatment Plant:
| Test | Limits for System+ |
| Total Plate Count | 79 CFU/ml |
| TOC | 1000 ppb |
| Coliforms including E. Coli/100 ml | Should be absent |
| Pseudomonas aeruginosa/100 ml | Should be absent |
| Staphylococcus aureus/100 ml | Should be absent |
| Salmonella species/100 ml | Should be absent |
TREND OF FEED (CHEMICAL & microbiological ANALYSIS) WATER analysis
The trend of Three Day chemical and microbiological analyses of raw water is as follows:
| Description | Limit | Day 01 | Day 02 | Day 03 | Result (Pass/Fail) |
| Colour | < 5 CTU | ||||
| pH | 7.5 | ||||
| Conductivity (us/cm) | 900 | ||||
| Turbidity | 1.8 | ||||
| SDI | Not check | ||||
| Total Dissolved Solids | 750 ppm | ||||
| Total Alkalinity | 120 ppm | ||||
| Total Hardness | 300 ppm | ||||
| Calcium as CaCO3 | 100 ppm | ||||
| Magnesium as CaCO3 | 200 ppm | ||||
| Sodium as Na | 36.11 ppm | ||||
| Potassium as K | 0.975ppm | ||||
| Sulphate as SO4 | 43.68 ppm | ||||
| Nitrates as NO3 | 2.3 ppm | ||||
| Chlorides as Cl | 92.3 ppm | ||||
| Flouride | 0.7 ppm | ||||
| Colloidal Silica | 5.6 ppm | ||||
| Reactive Silica | 5.6 ppm | ||||
| TOC | 1000 ppb | ||||
| Total Plate Count | 79 CFU/ml |
CALIBRATION REVIEW
Pressure Gauges:
| Test Instrument Number | Location of Test Instrument | Calibration Certificate |
| PG-05 | Top of Cartridge Filter | |
| PG-06 | Outlet of 5-micron Cartridge Filter | |
| PG-07 | Feed line of RO pass – I | |
| PG-08 | Reject line of RO pass – I | |
| PG-09 | Feed line of RO pass – II | |
| PG-10 | Reject line of RO pass – II | |
| PG-11 | Inlet Of EDI | |
| CIP-PG-01 | Discharge of CIPFP | |
| Verified By: | ||
Rotameter:
| Test Instrument Number | Location of Test Instrument | Calibration Certificate |
| RM-04 | inlet of RO System (RM-04) | |
| RM-05 | Reject line Of RO-I System(RM-05) | |
| RM-06 | Reject line Of RO-II System(RM-06) | |
| RM-07 | Feed line Of EDI (RM-07) | |
| RM-08 | Conc. line Of EDI (RM-08) | |
| Verified By: | ||
ORP Sensor, Transmitter & Controller:
| Test instrument Number | Location of Test Instrument | Calibration Certificate |
| ORP-01 | The inlet of the RO System | |
| Verified By: | ||
Conductivity Sensor, Transmitter & Controller:
| Test instrument Number | Location of Test Instrument | Calibration Certificate |
| CIC-01 | Outlet of RO pass – I | |
| CIC-02 | Outlet of RO pass – II | |
| CIC-03 | Outlet of EDI System | |
| Verified By: | ||
High Pressure Switch:
| Test instrument Number | Location of Test Instrument | Calibration Certificate |
| HPS-01 | Outlet of RO High-Pressure Pump I | |
| HPS-02 | Outlet of RO High-Pressure Pump II | |
| Verified By: | ||
Low Pressure Switch:
| Test instrument Number | Location of Test Instrument | Calibration Certificate |
| LPS-01 | The inlet of RO High-Pressure Pump-01 | |
| LPS-02 | The inlet of RO High-Pressure Pump-02 | |
| LPS-03 | Inlet of EDI | |
| Verified By: | ||
Level Sensor for CIP Tank:
| Test instrument Number | Location of Test Instrument | Calibration Certificate |
| CIP-LLS-01 | CIP Tank | |
| Verified By: | ||
Temperature Indicator & Transmitter:
| Test instrument Number | Location of Test Instrument | Calibration Certificate |
| CIP – TT-01 | CIP Feed Pump Discharge | |
| Verified By: | ||
Control Valves:
| Test instrument Number | Location of Test Instrument | Calibration Certificate |
| AV-02 | Before RO High Pressure – I | |
| AV-03 | Reject line of RO pass – I | |
| Av-04 | Permeate line of RO pass – I | |
| AV-05 | Reject line of RO pass – II | |
| AV-06 | Permeate line of RO pass – II | |
| Verified By: | ||
SAFETY INTERLOCK FEATURES TEST
| Interlock Description | Action Taken | Working (Y/N) |
| Low level in SMBS dosing tank | RO-EDI system will trip | |
| Low level in ADS dosing tank | RO-EDI system will trip | |
| Low level of pH dosing tank | RO-EDI system will trip | |
| A higher ORP value than the pre-set value | 1.) Free chlorine will pass through and the ORP sensor will sense free chlorine. In turn, the ORP value will increase above the set point. This will open the ORP dumping valve AV -02 2.) ORP comes down within the desired limit. After 30 secs. of consistent reading, below the set value, it will close the AV-02. Allow the water to feed to the RO system. The entire system will start automatically. 3.) If the ORP value is high for more than 300 secs. it will trip the plant. | |
| Low Pressure at ROHP-I suction | This will trip the ROHP-01 |
| High Pressure at ROHP-1 | RO-EDI System will trip | |
| High Conductivity at RO I outlet. | 1) If the Conductivity is above the set point, it will open the dumping valve AV-04 2) After 30 secs. of consistent reading, below the set value, it will close the AV-04Allow the water to feed to the RO II system. The entire system will start automatically. 3)If the RO outlet conductivity is high for more than 300 secs. it will trip the Plant | |
| Low Pressure at ROHP II suction. | This will trip the ROHP II | |
| High Pressure at ROHP II | System will trip | |
| High Conductivity at RO II outlet | 1) If the Conductivity is above the set point, it will open the dumping valve AV-06 2) After 30 secs. of consistent reading, below the set value, it will close the AV-06 Allow the water to feed to the EDI system. The entire system will start automatically. 3) If the RO outlet conductivity is high for more than 300 secs. it will trip the Plan |
| Interlock Description | Action Taken | Working (Y/N) |
| Low pressure at EDI inlet | Will trip the EDI unit | |
| High conductivity at EDI outlet | 1) If the Conductivity is above the set point, it will open the dumping valve FDV 01. 2) After 30 secs. of consistent reading, below the set value, it will close the FDV 01. Allow the water to feed to the purified water tank. The entire system will start automatically. 3) If the EDI outlet conductivity is high for more than 300 secs. it will trip the plant. | |
|
Auto Flushing | During High Level in the Purified Water Tank & If the plant is not operational for more than 60 mins. It will auto-flush the entire RO – EDI unit. ( For Settable Time) | |
| Emergency Stop | Should Trip the System | |
| Air Pressure Low | Will trip the system | |
| Auto Manual Switch Over | Will trip the System |
TRAINING
PERSONNEL TRAINING RECORD
| Training Details | Name | Trained By | Training Documented (Yes / No) |
FINAL REPORT
SUMMARY:
ANALYSIS / EVALUATION OF DATA:
Report approval.
The Operational qualification report for the Purified Water Generation System is reviewed and complies/does not comply with requirements.
Comments:
We certify that the Operational qualification report for the Purified Water Generation System is Accepted / Rejected.
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