VALIDATION PROTOCOL FOR COLLOID MILL MACHINE MODEL: CICM – 3 - HORIZONTAL Purchase Purchase Order No.: HPP!"!#3$ Da%ed &'-!&-
C() Mach(*er(es P+%. L%d. Works : Plot No.1&03, Phase Ph ase ", /. aradia teel U$it'3, G.".#.., at4a, Ahmedabad 380 026. G!arat, "N#"A.
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O01ECTIVE AND 2COPE:
"t is the ob!eti4e o5 this rotool to desribe i$ d etail the methodolo9y to be adoted ado ted to 4alidate the Homo olloid ill ahi$e, Plai$, GP odel with all o$tat arts 316, 5or se i$ the ma$5atri$9 roess. "t is to establish o$5ide$e that the Homo olloid ill ahi$e is aable o5 o$siste$tly oerati$9 withi$ established limits a$d tolera$e. +he rotool omrises o5 the 5ollowi$9. A: I*s%aa%(o* ua(4(ca%(o* % "t shold desribe the 5ollowi$9 1. E;ime$t sei5iatio$ as a9ai$st o$tai$ed i$ rhase order. 2. Utilities a$d ser4ies are roerly o$$eted. 3. ritial i$strme$ts < $eessary de4ies are alibrated a$d are attahed to the e;ime$t. *. ta$dard oerati$9 roedre are ide$ti5ied a$d writte$. ). a$5atrer=s erti5iate is ta>e$ whe$e4er $eessary. B: O)era%(o*a ua(4(ca%(o* % "t shold o4er the oerati$9 arameters set 5or the e;ime$t oeratio$. alidatio$ o5 e;ime$t a9ai$st these arameters shold also be desribed. "t shold also desribe. 1. E4alatio$ o5 roess oeratio$ with simlati$9 the rodt. 2. ?alitati4e < ?a$titati4e a$alysis o5 the simlated rodt. 3. erodibility o5 er5orma$e. : Per4or,a*ce ua(4(ca%(o* % "t shold o4er the er5orma$e arameters set 5or the e;ime$t er5orma$e. alidatio$ o5 e;ime$t a9ai$st these arameters shold also be desribed. "t shold also desribe. 01. E;ime$t 4alidatio$. 02. Per5orma$e ;ali5iatio$ e4alatio$. 03. i$al reort. E: Co*cus(o* % +he Homo olloid ill ahi$e meets the aeta$e riteria i$ re5ere$e to abo4e arameters are delared 4alidated a$d released 5or se.
o$5ide$tial "P AH"NE"E P+. 7+#.
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PAGE 2 o5 31
O01ECTIVE AND 2COPE:
"t is the ob!eti4e o5 this rotool to desribe i$ d etail the methodolo9y to be adoted ado ted to 4alidate the Homo olloid ill ahi$e, Plai$, GP odel with all o$tat arts 316, 5or se i$ the ma$5atri$9 roess. "t is to establish o$5ide$e that the Homo olloid ill ahi$e is aable o5 o$siste$tly oerati$9 withi$ established limits a$d tolera$e. +he rotool omrises o5 the 5ollowi$9. A: I*s%aa%(o* ua(4(ca%(o* % "t shold desribe the 5ollowi$9 1. E;ime$t sei5iatio$ as a9ai$st o$tai$ed i$ rhase order. 2. Utilities a$d ser4ies are roerly o$$eted. 3. ritial i$strme$ts < $eessary de4ies are alibrated a$d are attahed to the e;ime$t. *. ta$dard oerati$9 roedre are ide$ti5ied a$d writte$. ). a$5atrer=s erti5iate is ta>e$ whe$e4er $eessary. B: O)era%(o*a ua(4(ca%(o* % "t shold o4er the oerati$9 arameters set 5or the e;ime$t oeratio$. alidatio$ o5 e;ime$t a9ai$st these arameters shold also be desribed. "t shold also desribe. 1. E4alatio$ o5 roess oeratio$ with simlati$9 the rodt. 2. ?alitati4e < ?a$titati4e a$alysis o5 the simlated rodt. 3. erodibility o5 er5orma$e. : Per4or,a*ce ua(4(ca%(o* % "t shold o4er the er5orma$e arameters set 5or the e;ime$t er5orma$e. alidatio$ o5 e;ime$t a9ai$st these arameters shold also be desribed. "t shold also desribe. 01. E;ime$t 4alidatio$. 02. Per5orma$e ;ali5iatio$ e4alatio$. 03. i$al reort. E: Co*cus(o* % +he Homo olloid ill ahi$e meets the aeta$e riteria i$ re5ere$e to abo4e arameters are delared 4alidated a$d released 5or se.
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IN2TALLATION 5ALIFICATION E?U"PEN+ NAE E?U"PEN+ ANUA+UE ANUA+UE E?U"PEN+ 7/A+"/N 7/A+"/N
% H// /77/"# "77 AH"NE % "P AH"E"E P+. 7+#. 7+#. %
TABLE OF CONTENTS
01.0 01.0 E;i E;im me$ e$tt ea eat tre ress 02.0 02.0 Pre Pre ?al ?ali5 i5i iat atio io$ $ 03.0 03.0 tat tatem eme$ e$tt o5 Pr Pros osee 0*.0 0*.0 ta$ ta$da dard rd /er /erat ati$ i$9 9 Proe Proed dres res 0).0 0).0 "$st "$stal alla lati tio$ o$ he he>l >lis istt 06.0 #rawi$9s 0(.0 0(.0 or orti ti$9 $9 Util Utilit itie iess 08.0 08.0 #e5ii #e5iie$ e$y y a$d orre orreti ti4e 4e Ati Atio$ o$ eor eortt 0&.0 i$al e eort 10.0 10.0 Ae$d Ae$dii- ' e5ere e5ere$e $e #ome #ome$ts $ts..
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IN2TALLATION 5ALIFICATION 01.0 EQUIPMENT FEATURES
E?U"PEN+ NAE
% Homo olloid ill ahi$e.
/#E7 N/.
% " @ 3 Horio$tal odel ' Plai$
#EPA+EN+
%
A7"#A+"/N +EA
%
NAE
#E"GNA+"/N
"GNA+UE
#A+E%
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IN2TALLATION 5ALIFICATION 02.0 PRE 5ALIFICATION
#E"GN PAAE+E AN# APA"+% Homo olloid ill ahi$e @ Horio$tal Plai$ ' GP odel @ all o$tat arts 316
+AN#A# E?U"PEN+ / A#E A PE U+/E #E"GNA+"/N
% ta$dard E;ime$t
EN#/ E7E+E#
%
EN#E= A##E
% Plot No.1&03, G.".#., Phase ", /. aradia teeel U$it No. 3, at4a, Ahmedabad. G!arat ' 382 **)
ANUA+UE= NAE
%
+EA "N/7E# "N E7E+"/N / E?U"PEN+ AN# #E"GN
%
NAE
%
#E"GNA+"/N
%
"GNA+UE
%
#A+E
%
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IN2TALLATION 5ALIFICATION 02.1 PRE 5ALIFICATION E?U"PEN+ ?UA7""A+"/N A PE PUHAE /#E
% olloid ill ahi$e @ Horio$tal Plai$ @ GP odel @ all o$tat Parts 316
E?U"PEN+ EE"E# A PE P./.
%
AN #E"A+"/N
%
E+""A+"/N / EN#/ /
%
CA:
%
A+E"A7 / /N+U+"/N
AEP+E# / "N+A77A+"/N "N+A77A+"/N +EA
"N+A77A+"/N /P7E+E# /N
%
+HE E?U"PEN+ "N+A77A+"/N " A"E# /U+ A PE GU"#E7"NE AE# B +HE ANUA+UE.
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&6.6
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IN2TALLATION 5ALIFICATION
A+E"A7 < /P/NEN+
PE""E#
A+UA7
CAs sei5ied by ma$5atrer: Base
"G % 1
otor Hosi$9
"G % 1
3 way o>
"G % )
irlati$9 Pie
"G % )
ai$ Hosi$9 Assembly
"G % *
Hoer
"G % 1
e4iewed D "$seted by %
#ate %
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&6.3
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IN2TALLATION 5ALIFICATION
"+"A7 /P/NEN+ NAE Ha$d'wheel 5or 9a ad!stme$t betwee$ stator a$d rotor.
"#EN+""A+"/N N/. N. A.
PUP/E
or mahi$e miro 5i$e Ad!stme$t.
ANGE
) to 10 miro$s
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IN2TALLATION 5ALIFICATION 03.0 2TATMENT2 OF P5RPO2E +he rose o5 this rotool is to ro4ide a$ otli$e 5or the i$setio$ o5 e;ime$t 5or stati attribtes to 4eri5y that %
•
Eah i$stalled sb'omo$e$t omlies with the e$9i$eeri$9 desi9$ a$d e;ime$t data sheets < sei5iatio$s.
•
+he system is i$stalled aordi$9 to the desi9$ sei5iatio$s a$d ma$5atrers eomme$datio$s.
•
No $athoried or $reorded modi5iatio$s ha4e ta>e$ lae.
•
ta$dard /erati$9 Proedres ha4e bee$ ide$ti5ied a$d listed.
•
All sorti$9 tilities are roerly o$$eted.
•
All sa5ety 5eatres are ao$ted 5or.
•
All i$stallatio$'testi$9 reorts are a4ailable a$d mai$tai$ed o$ 5ile.
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IN2TALLATION 5ALIFICATION #.&
2TANDARD OPERATIN7 PROCED5RE
NUBE
E""/N
#A+E
/erati$9 lea$i$9 Pre4e$ti4e ai$te$a$e
omme$ts % History ard is reared 5or eah e;ime$t, whih i$ldes re4e$ti4e mai$te$a$e.
e4iewed D "$seted by% #ate%
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IN2TALLATION 5ALIFICATION &8.&
IN2TALLATION CHEC9LI2T Co*s(dera%(o*
No.
2%a%e,e*%
01.
03.
eri5y that the FAs BiltF drawi$9s are omlete a$d rerese$t the desi9$ o$et. eri5y that ma!or omo$e$ts are serely a$hored a$d roteted 5rom sho>. eri5y that there is $o obser4able hysial dama9e
0*.
eri5y that there is s55iie$t room 5or ser4ii$9 ro4ided
0). 06.
eri5y that all ii$9 a$d eletrial o$$etio$s ha4e bee$ do$e aordi$9 to the drawi$9s. All aess orts are e-ami$ed a$d leared o5 a$y debris.
0(.
al>i$9 aess to roo5 mo$ted e;ime$t ro4ided.
08. 0&.
e;ired eletri o$$etio$s are ti9ht weather roo5 a$d 9ro$ded. E;ime$t ide$ti5iatio$ $ame late is 4isible.
10.
Proer earthi$9 is made
02.
esNo
omme$ts% All the abo4e me$tio$ed o$sideratio$ are bei$9 he>ed a$d 5o$d satis5atory.
e4iewed D "$seted by%
#ate %
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IN2TALLATION 5ALIFICATION &'.&
DRA;IN72
#rawi$9s are ro4ided by the ma$5atrer a$d are omlete. 1. ahi$e GA #rawi$9 2. E-te$sio$ Hosi$9 Assembly 3. ai$ Hosi$9 Assembly *. o> Body Assembly ). iri$9 #ia9ram e4iewed D "$seted by %
#ate %
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IN2TALLATION 5ALIFICATION &<.&
25PPORTIN7 5TILITIE2
7ist the sorti$9 tilities a$d reord whether or $ot they are roerly o$$eted a$d ide$ti5ied. 5%((%=
Pro)er= Co**ec%ed a*d Ide*%(4(ed >esNo?
Eletrial o$$etio$ @ 3 hase
omme$ts % Utilities are roerly attahed.
e4iewed D "$seted by %
#ate %
Chec@ed =
Da%e
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IN2TALLATION 5ALIFICATION 08.0
DEFICIENC AND CORRECTIVE ACTION REPORT
#esritio$ o5 de5iie$y a$d date obser4ed% No de5iie$y 5o$d dri$9 i$stallatio$. Perso$ reso$sible 5or orreti4e atio$ a$d date assi9$ed% N.A. orreti4e atio$s ta>e$ a$d date o$dted % N.A. 2I7NAT5RE2
o$dted by% Aro4ed by%
#ate % #ate %
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IN2TALLATION 5ALIFICATION 0&.0
FINAL REPORT
0&.1
mmary % +he e;ime$t is rored as er sei5iatio$ o5
0&.2
A$alysis < E4alatio$ % +he mahi$e is i$stalled at the loatio$. orti$9 tilities are well o$$eted a$d 5$tio$i$9 roerly. ta$dard oerati$9 roedre are ide$ti5ied a$d listed. History ard is reared 5or the e;ime$t. All rele4a$t ritial dome$t a$d drawi$9 are slied by the ma$5atrer.
0&.3
erti5iatio$ % "$stallatio$ o5 olloid ill ahi$e is do$e a$d 5o$d satis5atory.
e4iewed D "$seted by %
#ate %
o$5ide$tial "P AH"NE"E P+. 7+#.
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IN2TALLATION 5ALIFICATION 10.0
APPENDIB
Abbre4iatio$s a$d #e5i$itio$ e5ere$e #ome$ts A: "$strtio$ a$al o5
"G % 1
otor Hosi$9
"G % 1
3 way o>
"G % )
irlati$9 Pie
"G % )
ai$ Hosi$9 Assembly
"G % *
Hoer
"G % 1
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IN2TALLATION 5ALIFICATION 10.1
APPENDIB >Co*%(*ued?
e5ere$e #ome$ts 01.
a$5atrers Brohre Cs: < a$al Cs: C+itle a$d 7oatio$:.
02. Prhase /rder. Attahed Ces < No.: "5 $o, state 7oatio$.
e4iewed D "$seted by %
#ate %
o$5ide$tial "P AH"NE"E P+. 7+#.
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OPERATIONAL 5ALIFICATION E5IPMENT NAME : HOMO COLLOID MILL MACHINE E5IPMENT MA9E : CIP MACHINERIE2 PVT. LTD. E5IPMENT LOCATION :
TA0 LE O F C O N TE N T2
1.0
ystem #esritio$
2.0
tateme$t o5 Prose
3.0
/P eri5iatio$
*.0
a5ety eatres +est
).0
imlatio$ o5 roess
6.0
ai$te$a$e hedle
(.0
i$al eort
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OPERATIONAL 5ALIFICATION &!.& 22TEM DE2CRIPTION
"P, Homo olloid ill ahi$e is a mahi$e 5or milli$9 o5 4isos li;id a$d aste. +he hoer aaity is 1) liters a$d eletrial motor 3 H, 28)0 P, 3 Phase. +he $it o$sists o5% • • • • •
otor Hosi$9 Assembly E-te$sio$ Hosi$9 Assembly ai$ Hosi$9 Assembly Hoer o> Body Assembly
+he seed o5 the rotor is 4ery hi9h. +o i$rease the 9a betwee$ stator a$d rotor, de'lo> the ha$dles by $srewi$9 the tr$ ad!sti$9 ri$9 by rotati$9 the ha$dles a$tilo>wise a$d to i$rease the milli$9 rotate the ha$dles lo>wise a$d also lo> the ha$dles. #e to the sli9htly de4iati$9 taeri$9 o5 the milli$9 sr5aes o5 stator a$d rotor, the 9a beomes $arrower towards the dishar9e setio$. +he seial desi9$ tye 5ailitates ad!stme$t o5 the 9ri$di$9 9a by a$ e-terior srew e4er dri$9 oeratio$. By three'way o> assembly we a$ re'irlate li;id tye rodt till yo 9et yor re;ired reslt. +he system has tilities li>e eletrial o$$etio$ a$d 4am o$$etio$ o$$eted to it.
o$5ide$tial "P AH"NE"E P+. 7+#.
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PAGE 20 o5 31
OPERATIONAL 5ALIFICATION NAME OF E5IPMENT: HOMO COLLOID MILL MACHINE &6.&
2TATEMENT OF P5RPO2E
+he rose o5 this rotool is to 4alidate the abo4e e;ime$t 5or the oeratio$al ;ali5iatio$ to 1. #emo$strate that the e;ime$t < system will er5orm rerodti4ity a$d o$siste$tly withi$ its 5ll dy$ami ra$9e o5 oeratio$ aordi$9 to ma$5atrers sei5iatio$s. 2. #ome$ts i$itial er5orma$e o5 the e;ime$t < system. 3. Assre that the e;ime$t < system er5orma$e is ade;ate to sort the roess 5or whih the system is desi9$ed. *. #emo$strate the sitability o5 the /P is established 5or the e;ime$t < system.
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OPERATIONAL 5ALIFICATION &3.& 2OP VERIFICATION :
b!et
% ta$dard /erati$9 roedre 5or the oeratio$ o5 Homo olloid ill ahi$e.
+esti$9 #ate
%
/erati$9 Perso$$el %
/bser4i$9 Perso$$el % Oser+a%(o*
Oser+a%(o* - es No >I4 *o s%a%e /h= (* co,,e*%s?
ost rre$t re4isio$ i$ se /erati$9 Perso$$el $dersta$d a$d 5ollow /P desritio$ a$d re;ireme$ts. /P ro4ides ade;ate diretio$ a$d o$trol to e$sre $i5orm e;ime$t oeratio$.
omme$ts % ahi$e is oerated as er ta$dard /erati$9 Proedre.
e4iewed D "$seted by %
#ate %
o$5ide$tial "P AH"NE"E P+. 7+#.
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PAGE 22 o5 31
OPERATIONAL 5ALIFICATION .&
2AFET FEAT5RE :
1. a5ety Pro4isio$ a9ai$st lea>a9e o5 the li;id% /il seals a$d /I ri$9s are ro4ided to a4oid the lea>a9e o5 the li;id a$d re4e$t the mai$ motor. "5 a$y seal will dama9e yo a$ see the li;id at the artilar ortio$, so by relai$9 that seal we a$ a4oid 5rther dama9e.
he>ed by #ate%
"$seted by% #ate%
o$5ide$tial "P AH"NE"E P+. 7+#.
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OPERATIONAL 5ALIFICATION &8.&
E5IPMENT VALIDATION THRO57H 2IM5LATION OF THE PROCE22.
+he simlatio$ o5 the roess was arried ot by milli$9 o5 the li;id or sse$sio$. 2(,ua%(o* o4 %he )rocess co*s(s% o4 %he 4oo/(* %
A:
illi$9 o5 li;id or sse$sio$ has bee$ do$e at desired artile sie a$d to he> it.
B:
Partile sie has bee$ he>ed 5or its e55eti4e$ess i$ dereasi$9 a$d i$reasi$9 o5 the 9a betwee$ the stator a$d rotor by ha$dles.
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OPERATIONAL 5ALIFICATION &8.! 2%ae Para,e%er 1. At a-imm illi$9 o$ditio$ 2. At /timm illi$9 o$ditio$ 3. At i$imm illi$9 o$ditio$
Loca%(o* 2a,)e 7i;id 5rom the o>e
Tes%s Partile sie redtio$
7i;id 5rom the o>e
Partile sie redtio$
7i;id 5rom the o>e
Partile sie redtio$
o$5ide$tial "P AH"NE"E P+. 7+#.
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&8.6 5ALIT CONTROL RE25LT
PH2ICAL APPEARANCE
A.
amle 5rom the Hoer be5ore milli$9
'
B.
amle 5rom the o$tai$er a5ter milli$9
'
PAGE 2) o5 31
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OPERATIONAL 5ALIFICATION &8.3
DATA EVAL5ATION AND CONCL52ION :
Based o$ the ;ality o$trol reslts 9e$erated by simlati$9 the roess a$d its re4iew, it a$ be said that mahi$e er5orms satis5atory a$d rodi$9 tablets o$5ormi$9 to the aeta$e riteria.
e4iewed by %
#ate %
o$5ide$tial "P AH"NE"E P+. 7+#.
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PAGE 2( o5 31
OPERATIONAL 5ALIFICATION &'.&
MAINTENANCE 2CHED5LE Chec@ (s%
.N/. 1 2 3 * ) 6
# J #aily
he> 5or lea$li$ess o5 hoer, stator, rotor, irlati$9 ie, 3 way o>. he> 4isally a$y lea>a9e o5 li;id 5rom e-te$sio$ hosi$9 de to oil seal or /I ri$9 dama9e he> the all rbber a>i$9 7briatio$ o5 9rease $iles o5 Hosi$9. he> motor mo$ti$9 bolts. he> < lea$ eletrial o$$etio$ a$d o$tat oi$ts
J ee>ly
J o$thly
"$seted by %
#ate %
# # #
o$5ide$tial "P AH"NE"E P+. 7+#.
A7"#A+"/N P/+//7 / H// /77/"# "77 AH"NE
PAGE 28 o5 31
OPERATIONAL 5ALIFICATION &<.&
FINAL REPORT
mmary A$alysis < E4alatio$
erti5iatio$ +he oeratio$ o5 the e;ime$t H// /77/"# "77 AH"NE was arried ot as er sta$dard oerati$9 roedre. +he e;ime$t er5orms withi$ the assi9$ed limits whe$ oerated as er aro4ed sta$dard oerati$9 roedre.
/erati$9 arameters that ha4e a si9$i5ia$t imat o$ the e;ime$t ability to oerate a$d ahie4e the roess are satis5atory a$d o$5orms to the aeta$e riteria. +he e;ime$t H// /77/"# "77 AH"NE /#E7 N/.
% " @ 3 H/"K/N+A7
#EPA+EN+
%
Prose
% illi$9 o5 4isos li;ids a$d astes.
re;e$y o5 alidatio$ % alidatio$ de o$ #ateor the e4e$t o5 a$y ha$9e i$ ritial omo$e$t o5 the mahi$e. F+HE E?U"PEN+ HOMO COLLOID MILL MACHINE " A7"#A+E# AN# E7EAE# / UE. #A+E
%
/L ANAGE
A"N+ENANE ANAGE
?.. ANAGE
?.A. ANAGE
o$5ide$tial "P AH"NE"E P+. 7+#.
A7"#A+"/N P/+//7 / H// /77/"# "77 AH"NE
PERFORMANCE 5ALIFICATION E5IPMENT NAME : HOMO COLLOID MILL MACHINE E5IPMENT MA9E : CIP MACHINERIE2 PVT. LTD. E5IPMENT LOCATION :
TA0 LE O F C O N TE N T2
1.0
tateme$t o5 Prose
2.0
i$al eort
PAGE 2& o5 31
o$5ide$tial "P AH"NE"E P+. 7+#.
A7"#A+"/N P/+//7 / H// /77/"# "77 AH"NE
PAGE 30 o5 31
PERFORMANCE 5ALIFICATION NAME OF E5IPMENT: HOMO COLLOID MILL MACHINE &!.&
2TATEMENT OF P5RPO2E
+he rose o5 this rotool is to 4alidate the abo4e e;ime$t 5or the er5orma$e ;ali5iatio$ to 1. +he e;ime$t < system will er5orm rerodti4ely a$d o$siste$tly withi$ its 5ll dy$ami ra$9e o5 er5orma$e aordi$9 to ma$5atrers sei5iatio$s. 2. #ome$ts i$itial er5orma$e o5 the e;ime$t < system. 3. Assre that the e;ime$t < system er5orma$e is ade;ate to sort the roess 5or whih the system is desi9$ed. *. #emo$strate the sitability o5 the /P is established 5or the e;ime$t < system.