EQUIPMENT QUALIFICATION

PROTOCOL NO.:
DEPARTMENT:
Page 1 of 12

TITLE: INSTALLATION QUALIFICATION PROTOCOL OF SS REACTOR

INDEX

S. No. Contents Page No.

1 Objective
2 Scope
3 Responsibilities
4 Reactor description & identification
5 Test of reactor
6 P& ID drawings
7 Components identification & description
8 Material of construction
9 Lubricants used
10 Verification & calibration of measuring & monitoring devices
11 Change/replacement spare parts
12 Identification and verification of utilities
13 Installation verification
14 Verification of safety features
15 Preventive maintenance
16 Acceptance criteria
17 Deviation report
18 Change control
19 Documentation
20 Installation qualification summary report
EQUIPMENT QUALIFICATION
PROTOCOL NO.:
DEPARTMENT:
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TITLE: INSTALLATION QUALIFICATION PROTOCOL OF SS REACTOR

1) Objective:
The objective of this protocol is to define procedure to conduct installation qualification of reactor

2) Scope:
This protocol is applicable for the installation qualification of SS reactor is to be installed
in Production Block at XXXXX

3) Responsibilities:
It is responsibility of the Maintenance department to prepare a protocol and perform the activities
as per the protocol and prepare the installation qualification report.
It is the responsibility of Quality assurance department to provide the training of equipment
qualification, review and approval of the protocol and report.
It is responsibility of the Quality assurance & Production department to ensure the execution of
qualification and co-ordinate in qualification study.
EQUIPMENT QUALIFICATION
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DEPARTMENT:
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TITLE: INSTALLATION QUALIFICATION PROTOCOL OF SS REACTOR

4) Reactor description & identification:

This shall describe the details of reactor being qualified, attached accessories and its operation along
with following details:

Sr. No. Description Details

1 Equipment code
2 Working capacity
3 Manufacturer Name
4 MOC
5 Agitator type
6 Stirrer RPM
7 Location
Observation:
4.1 Attached Accessories:

S. No. Description Details

MOC:
1 Vapor column Description:
Dimension:

Box type Primary condenser:

2
condensers Secondary condenser :
3 Bottom valve
Primary receiver:
4 Receiver
Secondary receiver:
5 Addition tank
Observation:
EQUIPMENT QUALIFICATION
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DEPARTMENT:
Page 4 of 12

TITLE: INSTALLATION QUALIFICATION PROTOCOL OF SS REACTOR

5) Tests of reactor:
This shall list the tests of reactor & test procedures required for its qualification.

5.1 Hydraulic test:

5.1.1 For Reactor:
Charge about 80% of the water in to the reactor. Close all opened nozzles of the reactor and
bottom valve. Apply hydraulic pressure to the reactor, test the pressure of reactor.
Acceptance criteria:
No leakage at 2.0 Kg/cm2.
5.1.2 For Limpet coils:
Apply water pressure to the limpet coil, close all opened nozzles of the outlet of limpet coils.
Apply hydraulic pressure and test pressure of limpet coil.
Acceptance criteria:
No leakage at 4.0 Kg/cm2.
5.2 MOC test:
Clean the surface of the equipment thoroughly where the test is carried out. Apply a drop of
electrolyte on the test material. Touch the graphite tip where the solution was applied on the test
material and switch on the torch. If the test material consists of molybdenum the color of
electrolyte turns into reddish pink, which concludes that the material is SS316. If the color of
electrolyte turns into black, the material is SS304.
Acceptance criteria:
MOC of reactor shell, top dish, bottom, stirrer & thermo well pocket & baffles should be SS316.
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DEPARTMENT:
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TITLE: INSTALLATION QUALIFICATION PROTOCOL OF SS REACTOR

5.3 Thickness test:

Conduct the thickness test for Shell, Top Dish, Bottom Dish and Limpet Coil from outside agency.
Acceptance criteria:
Vessel shell: 6-8 mm. Top Dish: 8-10 mm, Bottom Dish: 8-10 mm, Limpet Coil: 2-4 mm.

S. No. Test Specification Observations Checked by

Hydraulic test
1.1 Reactor No. Leakage at 2.0 Kg/cm2
1
1.2 Limpet coil No. Leakage at 4.0 Kg/cm2
MOC test
2.1 Shell SS316
2.2 Top Dish SS316
2.3 Bottom Dish SS316
2 2.4 Stirrer SS316
2.5 Thermo well pocket SS316
2.6 Baffles SS316
2.7 Reactor Support SS316
2.8 Limpet Coil SS316
Thickness test
3.1 Vessel Shell 6-8 mm
3 3.2 Top Dish 8-10 mm
3.3 Bottom dish 8-10 mm
3.4 Limpet Coil 2-4 mm
Observation:
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DEPARTMENT:
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TITLE: INSTALLATION QUALIFICATION PROTOCOL OF SS REACTOR

6) P&ID drawings:
This shall provide a proposed P & ID of reactor.
Refer proposed P & ID as annexure

7) Components identification & description:

This shall describe the major system components, including make, model, critical Parameter, location,
etc.
Actual
Description Acceptance Criteria Variance Checked by
Observations
Motor
1) Make Compton Greaves
2) Type Flame proof
3) RPM About 1450
4) HP 10.0 HP
Gear Box
1) Ratio 31.4:1
2) Oil grade Food grade
Agitator
1) Type Anchor with pitch blade
2) Shaft Diameter 90 mm
3) RPM About 48
Gland Box
1) Body MOC SS316
2) Mechanical Seal SS316

Installation consideration Status (Yes/No) Checked by

Properly mounted, supported & connected.
Properly labeled / Identified
Observation:
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DEPARTMENT:
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TITLE: INSTALLATION QUALIFICATION PROTOCOL OF SS REACTOR

8) Material of construction:
This shall include the list of all materials direct and indirect product contact. List is based on the
design specification. Items such as gaskets, valves and mechanical seal shall be included.
The details shall be documented as below:
8.1 Contact surface:

S. No. Components MOC Observations Checked by Remarks

1 Agitator SS316
2 Shell of the reactor SS316
3 Thermo well SS316
4 Bottom valve SS316
5 Gaskets Teflon

8.2 Non-contact surfaces:

S. No. Components MOC Observations Checked by Remarks

1 Motor Cast Iron
2 Reactor limpet coil SS304
3 Gear box Cast Iron
4 Mechanical seal SS316
Observation:
EQUIPMENT QUALIFICATION
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DEPARTMENT:
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TITLE: INSTALLATION QUALIFICATION PROTOCOL OF SS REACTOR

9) Lubricants used:
This shall include the list of lubricants required for the reactor components to operate. It shall be
documented as below:

S. No. Lubricants used Acceptance criteria Observations Checked by

1 Oil Food grade
2 Grease Food grade
Observation:

10) Verification & Calibration of Measuring & Monitoring Devices:

This shall include the calibration test certificate of measuring and monitoring devices that shall be
verified and documented as given below:
Calibrated
S. No. Critical components Reference No. Date of calibration Checked by
Yes/ No
Pressure /
1
Vacuum gauges
2 Safety valve
3 Temperature indicator
4 Temperature sensor
Observation:

11) Change / replacement spare part:

This shall include the list of spare parts for the reactor.

S. No List of spare parts Qty. Checked by

Observation:
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DEPARTMENT:
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TITLE: INSTALLATION QUALIFICATION PROTOCOL OF SS REACTOR

12) Identification and verification of utilities:

This shall document the identification and verification of utility connection meeting the specified
requirements to the reactor.

S.No Requirements Utility specification Verification Checked by

3 phase flame proof electric
1 Electrical connection
connection to be given.
DG backup should be
2 Electrical backup system
provided.

3 Lighting Lamp on light glass

Cooling water
Inlet : 1.5-3 inch
Chilled water
Outlet : 1.5-3 inch
Chilled Brine
4 Connection to be provided
Hot water
Steam Inlet: ¾ - 2 inch
Nitrogen & compressed air Inlet : ½ - 1 inch
5 Scrubber Inlet: 1.5 - 3 inch
6 Vacuum connection To receiver

Observation:
EQUIPMENT QUALIFICATION
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DEPARTMENT:
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TITLE: INSTALLATION QUALIFICATION PROTOCOL OF SS REACTOR

13) Installation verification:

The installation verification checks shall be documented in the given table.

S.No Considerations Actual (Yes/No) Checked by

Major components are securely anchored &
1
protected from shock.
2 Observable physical damage.
3 Sufficient area for servicing provided.
Electrical connections have been done
4
according to the drawing and grounded.
Reactor installed on foundation and secured in
5
Place.
The equipment is furnished with proper earthing
6
arrangements.
7 Supply of specified utility properly arranged.
8 Safety valve is provided for reactor.
9 Safety valve is provided for reactor limpet coils.
Observation:
14) Verification of safety features:
This shall document the safety features and shall verify the safety features meeting the specified
requirements.

S.No Parameters Observation Checked by

1 Safety guards for moving parts
2 Earthing
3 Lighting
4 Signs
5 Emergency stop accessible
Observation:
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DEPARTMENT:
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TITLE: INSTALLATION QUALIFICATION PROTOCOL OF SS REACTOR

15) Preventive maintenance:

Under this title, reference of the preventive maintenance procedures shall be recorded.

S.No Document Prepared/Modified Checked by

1 Preventive maintenance schedule
2 SOP
Observation:
16) Acceptance criteria:
It shall verify the test parameters are within the specified limit.
17) Deviation report:
This shall document any non-conformances observed during the verification of the installed reactor
along with the correction and compliance report.
17.1 Deviation observed:
S.No Specifications Actual Probable reasons Checked by

Observation:
17.2 Corrective actions of non conformance:
S.No Corrective action done Done by Checked by

Observation:

18) Change control:

The implementation of change shall be carried out through the change control system as per current
version of SOP.
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DEPARTMENT:
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TITLE: INSTALLATION QUALIFICATION PROTOCOL OF SS REACTOR

19) Documentation:
This shall include the installation qualification report, calibration certificates, test certificates etc.

20) Installation qualification summary report:

This shall summarize the installation qualification effort and shall present conclusion about
qualification status based on the IQ data.