Operational Qualification Protocol & Report for Air Compressor

OBJECTIVE

To establish documented evidence that AIR COMPRESSOR can operate within tolerances and limits.

Acceptance of Operation includes,

• To demonstrate the operational capabilities of Air compressors
• To ensure that air compressor is operating as intended and is under state of
• Operational features to meet process requirements and equipment specifications.

APPLICATION OF SOPs

Name	SOP number
Set-up & Operation SOP
Cleaning SOP

CONTROL PANEL TESTING

Name of the component: Main switch

Description	Specified	Remark	Checked By
‘ON’ switch	Should start the System	Yes
‘OFF’ switch	Should stop the System	Yes
Startup sequence	Not specified

INSTRUMENT CALIBRATION

Operational Description	Specified	Remark	Checked By
Pressure switch –for oil pressure	Shall maintain set   point	Yes
Auxiliary valve	Shall maintain set for loading and unloading	Yes
Safety valves	Shall control at set point.	Yes

OPERATIONAL TESTING

1. AIR PRESSURE TEST

OBJECTIVE:

To verify the air pressure delivered from compressor

To demonstrate that the Air compressor is balanced and is capable of delivering specified quantity of air.

INSTRUMENT USED: 

Pressure gauge

ACCEPTANCE CRITERIA: 

The pressure should not be less than 6 kg/ sq. cm at no load.

METHOD:

• Measure and record the air pressure at the air receiver tank.
• Monitor the reading after stabilization.

OBSERVATIONS:

SR. NO	LOADING TIME	PRESSURE OBSERVED (Kg/ sq cm)	REMARKS
1	4 min	10	OK
2	4min	10	OK
3	4min	10	OK

2. AIR LEAKAGE TEST

OBJECTIVE:

To demonstrate the integrity of compressor system

EQUIPMENT: 

Pressure gauge, stop watch

ACCEPTANCE CRITERIA: 

No leakage

METHOD:

1. Air compressor unit is to be in continuous operations when the test is being performed.
2. All the end valves must be closed
3. Record the loading time and unloading time continuously at air receiver tank for certain period.

OBSERVATION:

Sr. No	Unload Time(sec)	Load time (sec)	Remarks
1	3min 30sec	4min	OK
2	3min 30sec	4min	OK
3	3min 30sec	4min	OK

% Leakage = (load time/load time + unload time) ✖ 100

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3. AIR RECEIVER VESSEL PRESSURE TEST:

OBJECTIVE:

To demonstrate the maximum permissible pressure of vessel.

EQUIPMENT:

Hydraulic test.

ACCEPTANCE CRITERIA:

The maximum permissible pressure recommended is 150psi.

METHOD:

1. Put the system under pressure up to 100psig for 2hrs.and check for any pressure drop in order to identify the leakage from the chamber.
2. Prepare the soap solution and apply near the joints.
3. Observe the pressure drop every 15 minutes and record in the observation table.

OBSERVATIONS:

Sr. No	Time in min.	2 Standard Pressure (kg/cm)	Pressure Drop 2 (kg/cm)	Checked by
1.	15	9	0

Description of Non-Conformance

S. No.	Specifications	Actual	Probable reasons	Checked by
1.	Not in line with acceptance criteria	None	None

Correction of Non-Conformance

S. No.	Correction Done	Done by	Checked by
1.

Compliance Report

S. No.	Description of conformance	Checked by	Remarks
1	Complies with acceptance criteria		OK

Validation Team

Department	Name	Signature	Date
Maintenance
Production
Quality Assurance
Management

CONCLUSION: 

The AIR COMPRESSOR (Equipment Code: _____________) has been tested and verified for Operational Qualification as per the Services, Air COMPRESSOR Validation Protocol.

The Equipment is said to be Qualified as per the observations made therein.

APPROVED BY:

FUNCTION	NAME	SIGNATURE	DATE
Engineering
Production
Quality Assurance

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