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
- 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.
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 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
- 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,
- Fit the PG with vent valve on top nozzle.
- Connect Hydraulic pump to nozzle.
- When water flows out of vent, close the vent valve and develop pressure by pump till PG shows reading at specified Hydrostatic-test pressure.
- Mark the Pressure on the pressure gauge and check the same after 30 minutes.
- 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.
CYCLE OPERATION (RUNNING TRIAL)
NO. /TEST TO BE CARRIED OUT & PROCEDURE/ACCEPTANCE CRITERION
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”.
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”
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”.
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”
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”.
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“
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 “.
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”
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.
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.
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”
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”
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.
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”
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”.
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”.
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.
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”
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
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
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 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.
PURGING VALVE – Last column level high -Purging hold time -Shut down Timer after Process Stop
INTER LOCKING 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 which are installed on the plant as per approved DR.
Method Perform the operations sequence as indicated in manual.
Acceptance Criteria
Check operation sequence according to procedure given in operation and maintenance manual. As specified in Operation and Maintenance manual.
SUMMARY REPORT
Summary of the results obtained during OQ:
Significant deviations observed during OQ:
Conclusions:
For More Pharma Updates Visit –https://pharmaguidances.com
