Installation, Operational and Performance Qualification Report of Vacuum Tray Dryer (VTD)


  Equipment Name :Vacuum Tray Dryer
Equipment Model No.:XYZ
Equipment Sr. No.:XYZ
Equipment ID No.:VTD/XYZ
Equipment Area :Drying room
Equipment Manufacturer Name :
Equipment Application :For drying of wet granules and pellets
Report Date : 

REPORT APPROVAL:         

 Prepared byChecked byApproved by
Signature       
Date     
Name     
DepartmentMaintenanceQuality AssuranceProductionHead -MaintenanceHead – Quality Assurance
Corporate Office: –                                                                                XYZ Factory:-    
Sr. No.TitlePage No.
 Report approval ………………………………………………………1
 Table of contents ………………………………………………………2
 Abbreviations……………………………………………………………3
 Objective ………………………………………………………………4
 Scope …………………………………………………………………4
 Responsibilities …………………………………………………………4
 Equipment description …………………………………………………4
 Procedure ………………………………………………………………4
 Installation verification report …………………………………………4 – 5
 Technical specification verification report ……………………………6 – 8
 Sub components specification verification report ……………………8 – 9
 Measuring Device Calibration Verification Report……………………10
 Utility verification report…….…………………………………………10
 Safety features verification report ……………………………………10 – 11
 Material of construction (MOC) verification report ………………….11 – 12
 Test /inspection certificate verification report ……………………….12 – 13
 Operational functionality verification Report…………………………13 – 14
 Temperature verification report………………………………………15 – 16
 Performance verification report………………………………………16 – 17
 Deviation report ………………………………………………………18
 Change control………………………………………………………18
 List of annexure ……………………………………………………….18
 Summary and conclusion of qualification………………………………19
 Certification of qualification……………………………………………19

Abbreviations: 

Sr. No.AbbreviationFull Form
 °CDegree centigrade
 %Percentage
 ±Plus minus
 ACAlternative current
 cm2Square centimetre
 Dist.District
 DQDesign qualification
 HHeight
 HzHertz
 IDIdentification
 i.e.That is
 IQInstallation qualification
 kgKilogram
 LLength
 MIDCMaharashtra state industrial development corporation
 MOCMaterial of construction
 No.Number
 OQOperational qualification
 PQPerformance qualification
 PRProduction
 QAQuality assurance
 Qty.Quantity
 Sr.Serial
 SSStainless steel
 VVoltage
 VTDVacuum tray dryer
 WWidth
  1. OBJECTIVE:
    1. To record the findings of installation, operational and performance qualification of vacuum tray dryer having ID. No. VTD/XYZ.
2.0        SCOPE:
  • The scope of this report is limited to vacuum tray dryer having ID. No. P/PR/VTD/001.
  • 3.0 RESPONSIBILITIES:
    • Maintenance Officer/Executive:To prepare qualification report and co-ordinate the entire qualification activity.
    • Quality Assurance Officer/Executive: To witness the qualification study and ascertain that the study is conducted as per the protocol.
    • Production Officer/Executive: To execute qualification study in co-ordination with other departments.
    • Head Maintenance: To review the qualification documents.
    • Head Quality Assurance: To review and approve the qualification documents.
  • 4.0 EQUIPMENT DESCRIPTION:
    • AS per installation qualification protocol No.: XYZ/IQ/OQ/PQ/XYZ.
  • 5.0 PROCEDURE:

Qualification of the equipment should meet the acceptance criteria outlined in the following steps.

  • 5.1 Installation Verification Report
Sr. No.Check pointAcceptance Criteria (Specification)ObservationsChecked by Sign/Date
 1.0Visual inspection of the equipment. Visually there should not be any abnormality.  
 2.0Check the area of installation (Dryer area cubicle).Area of installation should have sufficient space for operation and servicing of the equipment.  
 3.0Check the levelling of the machine using level indicator.Air bubble shall be at centre position of level indicator.  
 4.0Check the major components and their electrical cables for housing and anchoring.Major components and their electrical cables shall be securely housed and anchored.  
 5.0Check the electrical ports.     All electrical ports shall be cleaned.  
 6.0Check the electrical circuit diagram.                                                                   All electrical connections shall be found connected as per electrical circuit drawing (reference No. DW-CE010)  
  • Technical Specification Verification Report
Sr. No.Check pointAcceptance Criteria (Specification)ObservationsChecked by Sign/Date
 1.0Loading capacity96 trays with approx 2 – 3 kg material in each trays  
 2.0DimensionApproximate 2750 (L) x 1900 (W) x 2400 (H) mm  
 3.0Heating shelfsHeating shelf’s shall be provided for holding and heating the trays.Sufficient distance shall be provided between two trays after mounting the trays on the shelfs.  
 4.0Door boltsDoor bolts shall be provided to lock the vacuum chamber door.  
 5.0Vacuum pumpVacuum pump facility shall be provided to generate the vacuum in the chamber.  
 6.0CondenserCondenser facility shall be provided for condensing the vapors drawn from vacuum chamber.  
 7.0ReceiverReceiver shall be provided to collect the condensate solvent and to draw vapour through vacuum pump.  
 8.0Digital temperature indicator cum controllerDigital temperature indicator cum controller shall be provided to control the incoming hot water temperature.  
 9.0Digital temperature indicatorDigital temperature indicator shall be provided to display the inlet temperature and product temperature of dryer.  
 10.0Circulation pumpCirculation pump shall be provided to circulate the hot water through drying equipment and tank.  
 11.0Vacuum break valveVacuum break valve shall be provided in front of equipment for easy access.  
 12.0Nitrogen purging valveNitrogen purging valve shall be provided in front of equipment for easy access.  
 13.0View glassView glass shall be provided in front of equipment to view the indoor material.  
 14.0Driving/electrical parts
 14.1Driving and electrical partsDriving and electrical parts shall be covered with SS304 material.There shall be separate cabinet for electrical parts to avoid pollutions from driving parts.  
 15.0Operating panel
 15.1Operating panelOperating panel shall be installed in front of equipment for easy access.  
15.2Emergency stop buttonEmergency stop button shall be provided on operating panel to stop the equipment in emergency.  
  • Sub Components Specification Verification Report
Sr. No.Check pointAcceptance Criteria (Specification)ObservationsChecked by Sign/Date
 1.0CondenserQty.: 1 No.  
 2.0ReceiverQty.: 1 No.  
 3.0Vacuum pumpQty.: 1 Set.  
 4.0Circulation pumpQty.: 1 Set.  
 5.0MotorQty.: 1 No.  
 6.0Sensor details
 6.1Incoming hot water temperature sensorQty.: 1 No.  
 6.2Inlet temperature sensorQty.: 1 No.  
 6.3Product temperature sensorQty.: 1 No.  
 7.0Electrical parts
 7.1Rupture disc/ Explosion ventQty.: 1 No.  
 8.0Pneumatic parts
 8.1Inlet control solenoid valveQty.: 1 Set  
 8.2Steam inlet control valveQty.: 1 Set  
 8.3Vacuum gaugeQty.: 1 Set  
  • 5.3 Measuring Device Calibration Verification Report
Sr. No.Measuring DeviceAcceptance CriteriaID. No./ Sr. No.Calibration  Done On and Calibration Due DateObservationChecked by Sign/Date
 MultimeterIt shall be within its calibration period.    
  • 5.4 Utility Verification Report
Sr. No.Utility parameterAcceptance Criteria (Specification)ObservationsChecked by Sign/Date
 1.0ElectricalThree phase 415 V AC ± 10% and 50 Hz ± 5%.  
 2.0Steam supplyNLT 6.0 kg/cm2  
  • 5.5 Safety Features Verification Report
Sr. No.Safety featuresAcceptance Criteria (Specification)ObservationsChecked by Sign/Date
 1.0EdgesEdges of construction shall be rounded.     
 2.0ElectricityThe equipment shall be earthed.  
 3.0Driving partDriving part shall be covered.  
 4.0Emergency stop buttonEmergency stop switch shall be provided.  
 5.0Sealing systemThe equipment shall consist of inflatable gaskets.  
 6.0Vacuum relief plate/explosion diskRupture disc provision shall be provided to opens at a pressure of 0.25 bar.  
 7.0Control panelControl panel shall be flameproof.  
  • 5.6 Material of Construction (MOC) Verification Report
Sr. No.ComponentAcceptance Criteria (Specification) for MOCObservationsChecked by Sign/Date
 1.0ChamberSS 316  
 2.0TraySS 316  
 3.0Heating shelfsSS 316  
 4.0CondenserSS 316  
 5.0ReceiverSS 316  
 6.0Support columns/legsSS 304  
 7.0Hot water distribution headersSS 304  
 8.0TankSS 304  
 9.0Steam inlet control valveSS 304  
 10.0Silicone rubber gasketsFood grade  
  • 5.7 Test/Inspection Certificate Verification Report
Sr. No.Check pointAcceptance Criteria (Specification)ObservationsChecked by Sign/Date
 1.0MotorIt shall be tested/inspected for its performance.  
 2.0Vacuum pumpIt shall be tested/inspected for its performance.  
 3.0Circulation pumpIt shall be tested/inspected for its performance.  
 4.0SensorIt shall be tested/inspected for its performance.  
 5.0Vacuum gaugeIt shall be tested/inspected for its performance.  
 6.0Control panel flame proofIt shall be tested/inspected for its performance.  
 7.0Rupture discIt shall be tested/inspected for its performance.  
 8.0Steam inlet control valveIt shall be tested/inspected for its performance.  
 9.0Wall panel insulation materialIt shall be tested/inspected for its performance.  
 10.0Vacuum tray dryerGuarantee/Warrantee certificate shall be provided.  

Note: Whether component is tested /inspected of its performance shall be verified based on the test/inspection certificate provided by the manufacturer.

  • 5.8 Operational Functionality Verification Report
Sr. No.OperationAcceptance CriteriaObservationsChecked by Sign/Date
 1.0Turn the main switch panel (red) ON/OFF button to ON position.Main panel shall turn ON.  
 2.0Turn the main switch panel (red) ON/OFF button to OFF position.Main panel shall turn OFF.  
 3.0Press (green) ON button of hot water pumpHot water pump shall turn ON.  
 4.0Press (red) OFF button of hot water pumpHot water pump shall turn OFF.  
 5.0Press (green) ON button of vacuum pumpVacuum pump shall turn ON.  
 6.0Press (red) OFF button of hot water pumpVacuum pump shall turn OFF.  
 7.0By pressing temp set (green) button set the hot water temperature at 90°C.Hot water temperature shall be entered successfully.  
 8.0By pressing up (green) button increase the set hot water temperature.Set hot water temperature shall increase successfully.  
 9.0By pressing down (green) button decrease the set hot water temperature.Set hot water temperature shall decrease successfully.  
  • 5.9 Temperature Verification Report
Sr. No.OperationAcceptance CriteriaObservationsChecked by Sign/Date
 1.0Set the hot water system temperature at 40°C and record the hot water inlet temperature and product temperature from temperature controller panel.For information only  
 2.0Set the hot water system temperature at 50°C and record the hot water inlet temperature and product temperature from temperature controller panel.For information only  
 3.0Set the hot water system temperature at 60°C and record the hot water inlet temperature and product temperature from temperature controller panel.For information only  
 4.0Set the hot water system temperature at 70°C and record the hot water inlet temperature and product temperature from temperature controller panel.For information only  
 5.0Set the hot water system temperature at 80°C and record the hot water inlet temperature and product temperature from temperature controller panel.For information only  
 6.0Set the hot water system temperature at 90°C and record the hot water inlet temperature and product temperature from temperature controller panel.For information only  
  • 5.10 Performance Verification Report
  • 5.10.1 LOD Report:

Minimum capacity of VTD:

Product Name :Batch No.:
Batch Size :
  Sr. No.Sample LocationLOD Result at InitialLOD Result at EndChecked by sign/date
 1.0Top Centre Tray   
 2.0Middle Centre Tray   
 3.0Bottom Centre Tray   
  • 5.10.2 LOD Report:

Maximum capacity of VTD:


Product Name :
Batch No.:
Batch Size :
  Sr. No.Sample LocationLOD Result at InitialLOD Result at EndChecked by sign/date
 Top Centre Tray   
 Middle Centre Tray   
 Bottom Centre Tray   
  • 5.10.3 Temperature mapping study report:

Temperature mapping study is carried out with maximum batch size (i.e. by loading 96 trays with approximately 2 to 3 kg material in each tray) with data recording interval of 15 min.


Product Name :
Batch No.:
Batch Size :
  • Minimum temperature location:
    • Highest fluctuation location:
    • Maximum temperature location:
  • 6.0 DEVIATION REPORT:
Sr. No.Deviation (s)Justification for acceptance criteriaImpact on installation, operation and performance
            
            
            
  • 7.0 CHANGE CONTROL:
  • 8.0 LIST OF ANNEX:
  • 9.0 SUMMARY AND CONCLUSION OF QUALIFICATION:
  • 10.0 CERTIFICATION OF QUALIFICATION:

Qualification is satisfactory.                                       Yes/No

Hence equipment can be used for routine use.           Yes/No

                                                                                                            Head – QA

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