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operational qualification GL reactor

Operational checks: Spark test ,Volume Calibration of reactor,check the stirring of reactor and current,Vacuum test & Test for Heating / Cooling 1) Volume Calibration of reactor Title : To check the calibration of reactor Test Objective : The objective of these tests is to ensure the volume calibration of reactor. Parameter Level Observed volume in Liters Checked by Volume calibration Stirrer touching volume Thermo well touching volume Over flow volume in vessel Jacket volume Comments:

2)Test to check the stirring of reactor and current: Title : To check the stirring of the reactor and current. Test Objective : The objective of these tests is to check and ensure that the reactor stirrer rotates in specified direction at specified RPM and draws specified current. Acceptance Criteria : The acceptance criteria are specified in the following table. Parameter Acceptance criteria Actual observation Checked by Test for RPM 48 rpm Direction of Rotation Clockwise No load current NMT ____ Amps Current with full load NMT ____ Amps Comments:

3) Vacuum test: Title : To check the vacuum functions in the reactor Test Objective : The objective of these tests is to check achieving and holding of vacuum in the reactor thus ensuring that all the joints are proper and the vacuum pump functions normal. Sr. No. Procedure Date Start Time End Time Duration Observation Checked By 1. Ensure all the openings of the reactor are closed. 2. Start vacuum pump

3. Open vacuum valve in the reactor 4. Wait till the vacuum in the reactor stabilizes. Vacuum achieved: __________ 5. Note down the vacuum reading. Vacuum reading: __________ (A) 6. Close the vacuum valve and hold vacuum for 15 minutes and note down the vacuum reading. Vacuum after 15 minutes hold time: ___________ (B) Vacuum drop in 15 minutes of hold time: = (A)-(B) = _________ Comments:

4) Test for Heating / Cooling : Title : To check the functions of the reactor Test Objective : The objective of these tests is to check the proper functioning of the reactor for functions like heating, cooling, reflux, distillation etc. to verify proper connections of Utilities. Sr. No. Procedure Date Start Time End Time Duration Observation Checked By 1. Charge 300L water/solvent Volume : ____ ltrs 2. Switch "ON" the reactor and heat up the mass till reflux starts. Temperature: Initial Temp: _____C Final Temp: _____C Steam Pressure: At header: _____kg/cm2 At jacket: _____kg/cm2 3. Reflux for 30 minutes. Temperature: Initial Temp: _____C Final Temp: _____C Steam Pressure: At header: _____kg/cm2 At jacket: _____kg/cm2 4. Distill for 1 hr. and record the volume distilled. Temperature: Initial Temp: _____C Final Temp: _____C Distilled Volume : __________ Liters Steam Pressure: At header: _____kg/cm2

At jacket: _____kg/cm2 5. Cool the mass to 30-40 C using RT water. Temperature: Initial Temp: _____C Final Temp: _____C RT Water Pressure: At header: _____kg/cm2 At jacket: _____kg/cm2 6. Cool the mass to 10-15 C using chilled water. Temperature: Initial Temp: _____C Final Temp: _____C Chilled Water Pressure: At header: _____kg/cm2 At jacket: _____kg/cm2 7. Cool the mass to 2 to 4 C using brine. Temperature: Initial Temp: _____C Final Temp: _____C Brine Pressure: At header: _____kg/cm2 At jacket: _____kg/cm2

How can you perform spark test in glass lined reactor? In-plant spark testing involves a 6000-volt source, either AC or DC. The voltage potential is applied across the clean, dry glass surface by an insulated, hand-held fault probe. Any exposed metal causes a visible spark to jump between the probe and the flaw, alerting the operator to its location.

While DC testing is preferred method, it can only be used on grounded equipment. Certain glass-lined equipment are totally encapsulated with glass so that they cannot be grounded.