Operational qualification for WFI generation plant

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 applies to multi-column water.

RESPONSIBILITIES

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 personnel will perform this test.

CHECK POINTS & TESTING

LIST OF REFERENCE DOCUMENTS

Objective: To check the documents required for the job as per the 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.

Hydrostatic Test Report SAT

Operation Qualification Report SAT

LIST OF REFERENCE DRAWINGS

  • G.A.Drawing
  • P & I Diagram
  • Wiring Diagram
  • Pneumatic diagram
  • PLC Logic Diagram

HYDROSTATIC TEST

Objective: To qualify the welding quality given Leak-tightness under Hydraulic pressured conditions as per the ASME code and qualify the vessel to operate at specified design conditions.

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 the vent valve on the top nozzle.
  3. Connect the Hydraulic pump to the nozzle.
  4. When water flows out of the vent, close the vent valve and develop pressure by pump till PG shows a 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 the 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.

CYCLE OPERATION (RUNNING TRIAL)

NO. /TEST TO BE CARRIED OUT & PROCEDURE/ACCEPTANCE CRITERION

EMERGENCY STOP

Press Emergency Stop -the 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 -The feed pump and Cooling Pump will restart, valves will get ON as per interlocking & dumping valve will get OFF. Check the display, it shows “PROCESS OK”.

AIR PRESSURE LOW:

Set the air pressure switch at a higher value than the 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 shows the fault “AIR PRESSURE LOW”

Set the Air pressure switch at a lower value than the actual air pressure.  The 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 shows “PROCESS OK”

BOILER STEAM TEMPERATURE LOW

Close the Plant Steam valve & wait till the Plant steam temperature is lower than the set plant steam temperature. The feed Pump will stop after 5 minutes & dumping valve will get ON. Check on the displays that show “BOI. STEAM TEMP. LOW”

Open the Plant Steam valve & wait till the Plant steam temperature is increased than the set plant steam temperature. The feed pump will restart, & dumping valve will get OFF. Check on the displays which show “PROCESS OK”.

DISTILL WATER LEVEL HIGH

Disconnect the wire loop given in the panel board for Auxiliary input, feed pump will stop Check the display which shows “DISTILL WATER LVL HIGH”

Now connect the wire loop given in the panel board for Auxiliary input, feed pump will restart Check the display which shows” PROCESS OK”

FEED WATER SUCTION PRESSURE LOW

Decrease feed water inlet pressure to less than the required pressure.  As soon as water pressure becomes less than required, the Feed Pump will stop Checking on the display which shows fault “INSUFF. FEED WATER”

Increase Feed water inlet pressure so that pressure is maintained. The feed Pump will restart and check on the displays which show “PROCESS OK”.

FEED WATER CONDUCTIVITY HIGH

Decrease the conductivity setting of the feed water set point less than the actual feed water conductivity. The feed Pump will stop checking on the display which shows fault “F.W. CONDUCT. HIGH”

Increase the conductivity setting of the feed water set point more than the actual feed water conductivity. The feed Pump will restart check on the display which shows fault  “PROCESS OK“

FEED WATER DISCHARGE PRESSURE LOW

Turn the pressure setting knob clockwise to set pressure more than the actual pressure, and check the display which shows fault “F. W. PRESSURE LOW”.

Turn the pressure setting knob Anti-clock-wise to set pressure less than the actual pressure. Check the display which shows “PROCESS OK “.

INSUFFICIENT EVAPORATION

Increase Feed water flow rate than required at standard temp of Boiler steam. Now accumulation of Feed water in the first column will start. Wait till the water level reaches the level sensor, as soon as the water reaches the level sensor, the Feed Pump will stop. Check on the display which shows fault “INSUFF. EVAPORATION”. (If we close the Ball valve connected before the steam trap it also result to increased accumulation of Feed water in the first column)

Now reduce the Feed water flow rate and set it standard flow rate required at the 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 shows “PROCESS OK”

PURGING ON PROBLEM

Stop Air supply given to Pneumatic Purging Valve. Increase Feed Water flow rate. Allow water to accumulate in the Last column till it reaches to level sensor (float switch).If the high level continues 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 that show “PURGING ON PROBLEM – RELEASE” and “PROCESS OK”. The purging valve will close after the purging time set parameter. If we press Acknowledge during fault condition Feed Pump will remain stop. Only after draining out the water Feed pump will start.

PURGING OFF PROBLEM

Decrease Feed Water Flow rates. Also, keep the Pneumatic Purging Valve open manually by turning the manual operating screw of the Solenoid Valve. If the high level not come continue more than the Purging Fault OFF time Feed Pump will stop. The display will show “PURGING OFF PROBLEM”.

Increase Feed Water flow rate & Keep the Pneumatic Purging valve in auto operation. Ensure that water should reach up to the level sensor. The purging valve will close after the purging time set parameter. If we press Acknowledge during fault condition Feed Pump will restart. Even if the water level is still high & again fault will be generated after the same purging fault OFF timer.

W.F.I CONDUCTIVITY HIGH

Decrease the set parameter value than existing conductivity. The dumping valve will be ON to reject the W.F.I. check on display which will Show. “W.F.I. CONDUCT. HIGH”

Increase the set parameter value then the existing Conductivity Dumping valve will OFF check on the display which shows fault “PROCESS OK”

W.F.I TEMPERATURE HIGH

Decrease the cooling water flow rate & wait till the W.F.I out temperature has 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 has become lower than the set value Check on display which will show ”PROCESS OK”

 W.F.I TEMPERATURE LOW

Increase the cooling water flow rate & Decrease Feed water flow rate; wait till the W.F.I. out temperature becomes lower than the set value.

Check on display which will show the “W.F.I. TEMP. LOW” dumping valve & air vent valve will get ON and the cooling pump will stop.

Decrease the cooling water flow rate & Increase the Feed water flow rate wait till the W.F.I. out temperature becomes higher than the set value. Check on display which will show “PROCESS OK” dumping valve & air vent valve will get OFF and the cooling pump will be on.

COOLING WATER TEMPERATURE HIGH

Decrease the cooling water flow rate & wait till the cooling water out temperature becomes 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 becomes lower than the set value. Check on display which will show “PROCESS OK”

FEED PUMP OVERLOAD

While the pump is running give a link between 24VDC and Feed Pump O/L.Immediately Feed pump will stop automatically Check the fault on Display “FEED PUMP O/L  “.

Now Again remove the link between them. As soon as the contact of the relay gets changed over Feed pump will start automatically checking the Display which shows the “PROCESS OK”.

COOLING PUMP OVERLOAD

While the pump is running give a link between 24VDC and Cooling Pump O/L.The immediately Cooling pump will stop automatically Check the fault on Display “COOLING PUMP O/L “.

Now Again remove the link between them. As soon as the contact of the relay gets changed over cooling pump will start automatically checking the Display which shows the “PROCESS OK”.

POWER FAILURE

Switch OFF the main panel. The entire panel will be off and the cycle will stop.

Switch ON the main panel. Now check on the print, which shows “POWER FAIL”. After the Power on Process will start from the same phase from where it is interrupted.

INSUFFICIENT COOLING WATER

Turn the pressure setting knob clockwise to set pressure more than the actual pressure.  Check the display that shows fault “INSUFF. COOLING WATER”

Turn the pressure setting knob Anti-clock-wise to set pressure to less than the actual pressure Check the display which shows “PROCESS OK”

FEED WATER DISCHARGE PRESSURE LOW    

Turn the pressure setting knob clockwise to set pressure more than the actual pressure, and check the display which shows fault “F. W. PRESSURE LOW”.

Turn the pressure setting knob Anti-clock-wise to set pressure to less than the actual pressure Check the display which shows “PROCESS OK “.

INTERLOCKING

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 Overload

COOLING PUMP -Cooling pump overload -Low W.F.I  temperature -Emergency Stop-Air Pressure Low – Insufficient cooling water.

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

AIR VENT VALVE -When the W.F.I. temperature is lower than the set value Air Vent Valve will be ON.-

The air vent valve will operate automatically as per the timer set in the parameter. It will operate for a set time at a set interval.

PURGING VALVE – Last column level high -Purging hold time -Shut down Timer after Process Stop

INTERLOCKING FOR CHILLED WATER IN VALVE (PNA3) – Emergency stop-Air Pressure Low

OPERATION SEQUENCE TEST REPORT

Objective: To carry out plant Operation sequence for observing performance/operation of all the items that are installed on the plant as per approved DR.

Method  Perform the operations sequence as indicated in the manual.

Acceptance Criteria

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

SUMMARY REPORT

Summary of  the results obtained during OQ:

Significant deviations observed during OQ:

ABBREVIATIONS

  • 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

Conclusions:

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