To describe a standard operating procedure for the operational qualification of different equipments.
1.0 PURPOSE:
To describe a standard operating procedure for the operational qualification of different equipments.
2.0 SCOPE:
The standard operating procedure describes in detail the method of the operational qualification of different equipments.
3.0 RESPONSIBILITY:
The responsibility of carrying out operational qualification of different equipments lies with the staff of rank not lower than the maintenance engineer.
The responsibility of preparing, reviewing and approving the standard operating procedure lies with the Manager - Maintenance, Head of Production and Head of QAD respectively.
4.0 METHOD:
4.1.0 Reactors:
4.1.1 Hydraulic Test of shell:
4.1.1a Fill the reactor with water fully by keeping the vent valve open. When water overflows from the vent, close the vent valve.
4.1.1b Test the equipment for welding joint leaks by applying hydraulic pressure. Apply the hydraulic pressure till the test pressure is reached. (1.5 times to the working pressure)
4.1.1c Close the hydraulic pump valve and observe the pressure for 2 Hrs. Pressure drops should not be there.
4.1.2 RPM Test:
4.1.2a Check the rpm of the motor with the help of techometer.
4.1.2b Switch "ON" the power supply.
4.1.2c Check the rpm of stirrer using tachometer.
4.1.3 Performance Test:
4.1.3a Fill the Reactor with water fully. Switch on the power supply and run the stirrer for one to two hours.
4.1.3b Check for any vibration, sound and heating up of the bearing housing and gear box.
4.1.4 Hydraulic test of jacket: Carry out hydraulic test as per SOP HYDRAULIC TESTING OF THE REACTOR JACKET..
4.2.0 Capacity Testing:
4.2.1 Fill the Reactor with water through flow meter to the lower neck of the manhole cover.
4.2.2 Record the volume of water and compare the volume with the specified capacity.
4.3.0 Heat Exchangers:
4.3.1 Check the positioning of Heat Exchanger with the spirit level.
4.3.2 Fill the Heat Exchanger shell with water, by keeping the vent valve open. Close the vent valve and apply hydraulic pressure till the test pressure (1.5 times to the working pressure) is reached.
4.3.3 Observe the pressure for 2 Hrs. pressure drops should not be there.
4.4.0 Receivers:
4.4.1 Capacity Testing:
4.4.1.1 The receiver is filled with water through calibrated flowmeter till the water just overflows.
4.4.1.2 Record the volume of water required.
4.4.2 Hydraulic Test:
4.4.2a Fill the receiver with water fully by keeping the vent valve open. When water overflows from the vent, close the vent valve.
4.4.3b Test the equipment for joint leaks by applying hydraulic pressure. Apply the hydraulic pressure till the test pressure is reached. (1.5 times to the working pressure)
4.4.3c Close the hydraulic pump valve and observe the pressure for 2 Hrs. Pressure drops should not be more than 10%.
4.5.0 Pumps:
4.5.1 Capacity Testing:
4.5.1.1 Pump water from a known volume tank and note the time taken to empty the tank.
4.5.1.2 From this capacity of pump can be determined.
4.5.1.3 Head of the pump can be determined by keeping the pressure gauge in the discharge line.
4.6.0 Vacuum Pumps
4.6.1 Capacity Testing:
4.6.1.1 Start the pump and close service valve.
4.6.1.2 Open water valve.
4.6.1.3 Record the vacuum produced (Shut-off-vacuum).
4.6.1.4 Open the pump valve and keep the pump in line to a reactor and record the vacuum developed at the reactor.
4.7.0 Centrifuges:
4.7.1 Switch-on the empty centrifuge and observe its speed. If it attains the maximum speed within 2 to 3 min. it shows centrifuge is in good condition and also observe for a dynamic balancing of the basket.
4.7.2 Load the centrifuge with material, observe the rotation and dynamic balancing of the basket for some time.
4.8.0 Pressure Filters:
4.8.1 Hydraulic Test
4.8.1a Fill the pressure filter with water fully by keeping the vent valve open. When water overflows from the vent, close the vent valve.
4.8.1b Test the equipment for leaks by applying hydraulic pressure. Apply the hydraulic pressure till the test pressure is reached. (1.5 times to the working pressure).
4.8.1c Close the hydraulic pump valve and observe the pressure for 2 Hrs. Pressure drops should not be there.
4.9.0 Leaf Filters:
4.9.1 Hydraulic Test
4.9.1a Fill the leaf filter with water fully by keeping the vent valve open. When water overflows from the vent, close the vent valve.
4.9.1b Test the equipment for leaks by applying hydraulic pressure. Apply the hydraulic pressure till the test pressure is reached. (1.5 times to the working pressure).
4.9.1c Close the hydraulic pump valve and observe the pressure for 2 Hrs. Pressure drops should not be there.
4.10.0 Sifter :
4.10.1 RPM Test:
4.10.1a Check the rpm of the motor with tachometer.
4.10.1b Switch "ON" the power supply.
4.10.1c Observe the effective shaking of the sieve.
4.11.0 Double Cone Blender
4.11.1 Capacity Testing:
4.11.1a Fill the blender with water through flowmeter.
4.11.1b Record the volume of water.
4.11.2 RPM Test:
4.11.2a Switch ON the power supply to the blender.
4.11.2b Using tachometer measure the RPM of blender.
4.12 RECORDING:
The responsibility recording the observation in the O.Q. protocol Annexure lies with the staff of rank not lower than the maintenance engineer.
Different equipments, maintenance engineer, engineering
