Chicago Pneumatic Compressors

INSTALLATION QUALIFICATION
Equipment / System Compressed Air System
Document No. CP/IQ/ACME/002 Effective Date
Supersedes None Page Number 1 of 28

INSTALLATION QUALIFICATION
PROTOCOL
COMPRESSED AIR SYSTEM

Manufacturer CHICAGO PNEUMATIC

Model Number PX-60-7-A-E

Equipment Identification Number PNB-920654

 Chicago Pneumatic Compressors

INSTALLATION QUALIFICATION
Equipment / System Compressed Air System
Document No. CP/IQ/ACME/002 Effective Date
Supersedes None Page Number 2 of 28

Index

Sr. No. Contents Page No.

1 PROTOCOL APPROVAL 3

2 OVERVIEW 4

3. RESPONSIBILITY 5

4. SYSTEM IDENTIFICATION LOCATION 6

5. SYSTEM DESCRIPTION 8

6. ACCEPTANCE CRITERIA 11

7. INSTALLATION QUALIFICATION CHECKS 12

8. REQUALIFICATION 31

9 FINAL REPORT 32

10. REPORT APPROVAL 33

11. APPENDIX 34
 Chicago Pneumatic Compressors

INSTALLATION QUALIFICATION
Equipment / System Compressed Air System
Document No. CP/IQ/ACME/002 Effective Date
Supersedes None Page Number 3 of 28

1.0 Protocol Approval

Signing of this Approval page of Installation Qualification Protocol indicates agreement with
the Installation Qualification approach described in this document. Should Modifications to
the Installation Qualification become necessary, an addendum will be prepared and approved.

Prepared By Signature Date

Reviewed By Signature Date

Approved By Signature Date

 Chicago Pneumatic Compressors

INSTALLATION QUALIFICATION
Equipment / System Compressed Air System
Document No. CP/IQ/ACME/002 Effective Date
Supersedes None Page Number 4 of 28

2.0 Overview
2.1 Objective
The objective of this Protocol is to provide a written guideline for carrying out the
Installation Qualification (IQ) of Compressed Air Generation System.

2.2 Scope
This protocol is applicable to Installation Qualification of Compressed Air generation
System (PNB-920654) supplied by M/s CHICAGO PNEUMATIC COMPRESSORS
against the Purchase Order and installed in the Utility block at the ground floor.
2.3 Statement of Purpose

The purpose of this protocol is to provide an outline for Installation Qualification

of the System for static attributes to verify that:
2.3.1 The system is installed according to the design specifications and manufacturers
recommendations.
2.3.2 Each installed subcomponent complies with the engineering design and system
data sheets/specifications given by the manufacturer.
2.3.3 The system meets the current Good Manufacturing Practices (cGMP) requirements
and all other regulatory obligations.
2.3.4 No unauthorized or unrecorded modifications have taken place.
2.3.5 Standard Operating Procedures have been identified and listed.
2.3.6 All critical instrumentation has been identified for calibration.
2.3.7 All supporting utilities are properly connected.
2.3.8 All installation-testing reports are available and attached.
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INSTALLATION QUALIFICATION
Equipment / System Compressed Air System
Document No. CP/IQ/ACME/002 Effective Date
Supersedes None Page Number 5 of 28

3.0 Responsibility:
The validation group comprising of representatives from each of the following departments
shall be responsible for the overall compliance of this protocol:

Department Responsibility
Execution of IQ Protocol, recording the
Engineering
data, and review of IQ document and

summary report. Compiling the data,

and preparation of summary report.

Production Review of IQ document and summary

report

Final review of the qualification

Quality Assurance
documents and its compliance to meet

the acceptance criteria of the

Installation Qualification protocol.

Approval of summary report.

Name Signature Date

Details Entered By

Verified By
 Chicago Pneumatic Compressors

INSTALLATION QUALIFICATION
Equipment / System Compressed Air System
Document No. CP/IQ/ACME/002 Effective Date
Supersedes None Page Number 6 of 28

4.0 System Identification

Record the following information in Table I,

Table I
Required Information As-Found Condition
The subjected equipment is
RECIPROCATING AIR COMPRESSOR
identified as
Name and address of the CHICAGO PNEUMATIC
COMPRESSORS,
Manufacturer
PUNE

Purchase Order Number / Date

PX-60-7-A-E
Model No.

PNB-920654
Equipment Identification Number

System Location

Department ENGINEERING

Department Code ENGG

Floor GROUND

Area UTILITY-1/2/3

Name Signature Date

Details Entered By

Verified By
 Chicago Pneumatic Compressors

INSTALLATION QUALIFICATION
Equipment / System Compressed Air System
Document No. CP/IQ/ACME/002 Effective Date
Supersedes None Page Number 7 of 28

5.0 System Description

5.1 General description
The Compressed Air System is designed to provide Quality compressed Air, which is used,
for the process, non-process, instrumentation and control applications. The term ‘Quality
Air’ is applied to the air which is free from:
1) Dust, dirt and other foreign particles
2) Oil
3) Moisture
The Compressed Air System comprises of following units.
1) Air Compressor
2) Air Dryer
3) Air Filters
4) Compressed Air storage & distribution Network.
All these units are briefly described as below. The Compressed Air System comprises of
following units.
1) Air Compressor
2) Air Dryer
3) Filters
4) Compressed Air storage & distribution Network.
All these units are briefly described as below.
1) Air Compressor: The air compressor produces compressed air by sucking the available ambient air at
site, compressing it and delivering it to the required pressure. The Air Compressor is two stage .

Basic components of the Air Compressor are

a) Compressor
b) Air Oil Receiver Tank
c) Cooler Assembly
d) Motor
e) Control Panel
f) Acoustic Canopy & Drive Arrangement
 Chicago Pneumatic Compressors

INSTALLATION QUALIFICATION
Equipment / System Compressed Air System
Document No. CP/IQ/ACME/002 Effective Date
Supersedes None Page Number 8 of 28

g) Pre- Filter Panel

h) Air Outlet

A brief description of all the above said sub units are as below: -
Compressor:
a) Two Stage, Rotary Screw Element Complete With: -
b) Dry Paper Type Suction Air Filter With Silencer ; Conveniently Located For Easy Replacement Of Filter
Element
c) Un-loader With Integrated Regulating Valve For Load/Unload Control System ; Simple Design With Only
One Moving Part, Needs No Regular Adjustments
d) Three-Way Solenoid Valve Required for Load/Unload Regulation Of The Compressor
e) Air / Oil Temperature Sensor To Sense Air Oil Temperature At Element Outlet And To Shut Down The
Compressor In Case Of High Element Outlet Air Temperature
f) Air Check Valve At The Element Discharge .
Air-Oil Receiver Tank:
 Pointer Indication For Oil Level And Oil Filling Arrangement
 Minimum Pressure Valve To Close Off The Compressor From The Air Net When The Unit Is Stopped Or
Running Unloaded And To Maintain Required Air Pressure In The System For Proper Oil Lubrication.
 Safety Valve
 Air-Oil Receiver Pressure Gauge
 Oil Draining Arrangement
 Three Stage Air Oil Separation System
o First By Cyclonic Action (Centrifugal),
o Second By Gravitational (Heavier Particles Separate Down),
o Third By Passing Through Coalescent Filter

Air & Oil Cooler Assembly :

 Air & Oil Cooler Are Independent & Compact Block Coolers Of Aluminum For:-
o Optimum Heat Transfer.
o Lower Pressure Drop
o Lower Weight.
o Suitable for 460 C
 After Cooler Reduces The Temperature Of Outlet Air To Approximately 8 To 100 C Above Ambient
Temperature.
 Oil Filter Mounted On Manifold Block For Filtration Of Lubricating Oil
 Thermostatic Valve To Regulate Oil Temperature Within The System.
 Cooling Fan With Fan Motor For More Effective Cooling.

Motor :
2 Pole, Squirrel Cage Induction Motor With TEFC IP 55 Enclosure, Class F Insulation, Suitable For 46 0 C Ambient
Temperature And 400 +/- 10% Volts, 3phase, 50 +/- 3% Hz Supply
Motor Non drive end bearings greased for life.
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INSTALLATION QUALIFICATION
Equipment / System Compressed Air System
Document No. CP/IQ/ACME/002 Effective Date
Supersedes None Page Number 9 of 28

Power And Control Panel :

Power Panel Incorporating;
- Power isolation contactor (Optional)
- Inverter Drive of Danfoss make, 380 – 480 V AC.
- Monitors and controls the speed of the unit for optimum compressed air delivery based on air system
working pressure, resulting in constant pressure availability in the Air net along with substantial power
saving. Emergency Stop Button.
-
Acoustic Canopy & Drive Arrangement:
 Compressor Package Is Enclosed In A Powder Coated Acoustic Canopy With Sound Absorbing Material For
Limiting The Noise Level.
 Canopy Is Pressurized Ensuring No Pressure Drop At Suction Filter And Avoids Entry For Dust Particles In
The Element
 Anti Vibration Mounts Support Electric Motor And Compressor Unit And Isolate The Moving Components
From Rest Of The Structure, Thereby Reduces Sound Level And Avoids Need For Anchoring The Machine
On Floor.
 Direct Gear Drive Arrangement For Efficient Power Transmission.
Pre-filter Panel:
 Suitably Sized Pre-filtering Arrangement For The Air Entering The Canopy Of Compressor Unit.
Easily Removable For Cleaning Purpose.

3.0 Compressed Air storage & distribution Network: The compressed air produced by the air compressor is
stored in an air receiver (Storage tank). From the air receiver tank the compressed air is made available to the
Refrigerated type of air drier/ or to and application.

5.2 Major Components

Sr. No. List Of Major Components.

1 Air Compressor
2 Air Dryer
3 Air Line Filters
4 Air Storage and Distribution Network
 Chicago Pneumatic Compressors

INSTALLATION QUALIFICATION
Equipment / System Compressed Air System
Document No. CP/IQ/ACME/002 Effective Date
Supersedes None Page Number 10 of 28

Name Signature Date

Details Entered By

Checked By

6.0 Acceptance Criteria

Installation Qualification shall be considered acceptable when the requirements specified
in the test data sheets covered in the Installation Qualification Checks list have been
met.
Any deviation from the acceptance criteria of the specific checkpoint shall be reported and
decision shall be taken for the rejection, replacement or rectification of the
equipment/component.
 Chicago Pneumatic Compressors

INSTALLATION QUALIFICATION
Equipment / System Compressed Air System
Document No. CP/IQ/ACME/002 Effective Date
Supersedes None Page Number 11 of 28

7.0 Installation Qualification Checks

7.1 Installation Check List

Checked by
Sr. Statement Observations
(Sign / Date)
No.
The "As Built" drawings are complete and represent the
1.
design concept.
The major components are securely anchored and
2.
protected from shock.
3. There is no observable physical damage.

4. There is sufficient room for servicing and cleaning.

The piping and electrical connections have been done

5.
according to the drawings.
All pipes and connections are properly concealed, dressed
6.
and covered to facilitate cleaning.

7. All access ports are examined and cleared of debris.

The required electric connections are tight, weather proof

8.
and grounded.
The wiring diagram is glued or taped to inside section of
9.
the control panel.
The equipment identification nameplate along with
10.
equipment number is visible.
The units are installed on foundation and secured in place
11.
as per manufacturer's recommendations.
12. The machine manual is available.

Name Signature Date

Verified By
 Chicago Pneumatic Compressors

INSTALLATION QUALIFICATION
Equipment / System Compressed Air System
Document No. CP/IQ/ACME/002 Effective Date
Supersedes None Page Number 12 of 28

7.2 Inspection Checklist

Instructions:
o Identify the critical components of equipment and verify that the components are

complying as per desired specifications. Record the observations in the Data Sheet.

o Check the MOC of the component as per the instruction mentioned. Record the

observation of the MOC in the Data Sheet.

o Check the installation of equipment:

 To check the leveling and alignment as per the procedure and record the observation

in the Data Sheet.

 To verify the proper assembly of the components as per the equipment Drawings.

o Identify the utility supplies required for equipment operation. Verify that utilities are as per

the specification mentioned in the Check list. Record the observation in the Data Sheet.

o List the available drawings.

o Identify the SOPs and assign SOP Numbers, record the SOP Title and Number.

o Record the deficiency (if any) and report the details of action taken.

 When more than one unit of the same type exists, replicate the corresponding

data sheets to match and uniquely identify each page.

 Wherever specifications are not mentioned, record the observations as per the

statement of the data sheet.

 Chicago Pneumatic Compressors

INSTALLATION QUALIFICATION
Equipment / System Compressed Air System
Document No. CP/IQ/ACME/002 Effective Date
Supersedes None Page Number 13 of 28

7.3 Major Component Verification

Objective: - To verify that major components as identified below are complying as per the
desired specifications.
7.3.1 TEST DATA SHEET
Sr.
Test Particulars Specifications Observation Checked By
No. (Sign/Date)

1.0 Name of the Component - Air Compressor

1.1 Check the machine No physical damage should be

frame, cylinder, observed.
suction filter housing,
after cooler, pipe lines
and auto-drain valve
for any physical
damage.
1.2 Check the nameplate Make : Chicago Pneumatic
details of the Type : PX-60-7-A-E
Compressor. FAD (cfm):332
Discharge pressure : 7Kg/cm²
Sr.No. – PNB 920654
Year : 2021

1.3 Check the Motor for There should be no physical

any physical damage. damage.
1.4 Check the 'V' belt and There should be no physical
pulley for any physical damage.
damage.
1.5 Check for nameplate Make-Crompton Greaves
details of motor. Power: 45 kW (60 HP)
Sr.No: PNB 920654
50 Hz, Current –63 Amps
 Chicago Pneumatic Compressors

INSTALLATION QUALIFICATION
Equipment / System Compressed Air System
Document No. CP/IQ/ACME/002 Effective Date
Supersedes None Page Number 14 of 28

Sr.
Test Particulars Specifications Observation Checked By
No. (Sign/Date)
1.6 Check the Make: -Rotex
specifications of Connection: ½” BSP (F)
Automatic Drain Voltage: -220VAC.
valve. Max. Pressure:
1.7 Check the No physical damage should be
Load/Unload solenoid observed.
valve for any physical
damage.
1.8 Check the Make: --Rotex
specifications of Valve Type:
Load/Unload solenoid Max. Pressure: 10 kg/cm2
1.9 valve.
Check the No physical damage should be
Load/Unload pressure observed.
transducers for any
physical damage.
1.10 Check the Low Oil No physical damage should be
Pressure for any observed.
physical damage.
1.11 Check the Make: - Chicago Pneumatic
specifications of Low Max press –0-3Kg/cm2
Oil pressure Pump.
1.12 Check the Electrical No physical damage should be
Control Panel for any observed.
physical damage.
1.13 Check all the electrical No physical damage should be
switchgears, terminals, observed.
and power and control
wiring for any
physical damage and
loose connections.
 Chicago Pneumatic Compressors

INSTALLATION QUALIFICATION
Equipment / System Compressed Air System
Document No. CP/IQ/ACME/002 Effective Date
Supersedes None Page Number 15 of 28

Sr.
Test Particulars Specifications Observation Checked By
No. (Sign/Date)
1.14 Check the No physical damage should be
Programmable Logic observed.
Controller for any
1.15 Check thedamage.
physical Make: -CP Tronix III
specifications of Sr.No:-
Programmable Logic
Controller.
1.16 Check the Human .No physical damage should be
Machine Interface for observed
any physical damage.
1.17 Check the No physical damage should be
communication cable observed
between PLC and
HMI for any physical
damage.

2.0 Name of the Component Air Dryer

2.1 Check the Air Dryer There should not be any physical
for any physical damage.
damage.
2.2 Check the Make – Chicago Pneumatic
specification of the Compressors
Air Dryer. Voltage: 230 Volt , 50 Hz.

3.0 Name of the Component Air Receiver

3.1 Check the Air There should be no physical
Receiver tank for any damage.
 Chicago Pneumatic Compressors

INSTALLATION QUALIFICATION
Equipment / System Compressed Air System
Document No. CP/IQ/ACME/002 Effective Date
Supersedes None Page Number 16 of 28

Sr.
Test Particulars Specifications Observation Checked By
No. (Sign/Date)
for any physical
damage.
3.2 Check the name plate NA -
details of the air
receiver tank

3.3 Check the dimensions NA-

of the Air Receiver
tank.

Name Signature Date

Verified By

7.4 Material of Construction

 Chicago Pneumatic Compressors

INSTALLATION QUALIFICATION
Equipment / System Compressed Air System
Document No. CP/IQ/ACME/002 Effective Date
Supersedes None Page Number 17 of 28

Material of Method /
Sr. construction Reference used Checked by
Component
No. Specified Actual for verification
(Sign / Date)

1 Compressor

Air Dryer -
2

3 Air Receiver -

Comments:
___________________________________________________________________
__________________________________________________
________________________________________________________

Name Signature Date

Verified By
 Chicago Pneumatic Compressors

INSTALLATION QUALIFICATION
Equipment / System Compressed Air System
Document No. CP/IQ/ACME/002 Effective Date
Supersedes None Page Number 18 of 28

7.5 Verification for Installation

7.5.1 Leveling and alignment.

Method / Checked by
Observation
Sr. Reference used
Component (Sign / Date)
No. for verification
1 Levelling of the Base Frame of

Air Compressor Skid

2 Alignment of motor and air

compressor pulley

3 Levelling of base frame of air

dryer

Comments: _____________________________________________________

_________________________________________________

__________________________________________________

Name Signature Date

Verified By
 Chicago Pneumatic Compressors

INSTALLATION QUALIFICATION
Equipment / System Compressed Air System
Document No. CP/IQ/ACME/002 Effective Date
Supersedes None Page Number 19 of 28

7.5.1.1 Method for checking the Leveling of the Equipment

7.5.1.1.1 Using Spirit Level Indicator

 Place the spirit level indicator at different points on the machine frame.

Acceptance Criteria:

The air bubble of the spirit level indicator shall be observed in the center.

7.5.1.1.2 Using Water Level Indicator

 Place transparent tube filled with water of suitable length at various corners. Compare

the levels of water and align the equipment

Acceptance Criteria:

The water level at both the locations should match with the edges of those locations, if

required should be repeated for other edges of the equipment on same plane.
 Chicago Pneumatic Compressors

INSTALLATION QUALIFICATION
Equipment / System Compressed Air System
Document No. CP/IQ/ACME/002 Effective Date
Supersedes None Page Number 20 of 28

7.5.2 Location and Assembly

S. Checked by
Test Particulars Observation
No. (Sign / Date)
1. Check that equipment is
installed in the Room
specified in Equipment
Layout
2. Check that assemblies of
component are as per
the General
Arrangement Drawing.

Name Signature Date

Verified By
 Chicago Pneumatic Compressors

INSTALLATION QUALIFICATION
Equipment / System Compressed Air System
Document No. CP/IQ/ACME/002 Effective Date
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7.6 Supporting Utilities

List the supporting utilities, verify their specifications and record whether they are
connected and identified.

Connected and Checked by

Sr. Utility Specified Measured Results Identified
(Sign / Date)
No. (Yes / No)
3 Phase, 415 Volt

1 Electrical Power  10%

50 Hz.  3%

Name Signature Date

Verified By

Name Signature Date

Checked By

7.8 Drawings
Attach a copy of all relevant drawings and list below. Categorize the drawings as follows:
A. Piping and Instrumentation Diagram (P&ID).
B. General arrangement / Schematic line diagram.
C. Utility
D. Electrical (Starter Circuit & Service Diagram)
 Chicago Pneumatic Compressors

INSTALLATION QUALIFICATION
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Drawing Details Drawings

Attached
S.No. Title Category Drawing No. Date Rev. No. Yes/No
1. General
Yes
arrangement of Air GA
compressor system

Name Signature Date

Verified By

7.9 Standard Operating Procedures (SOPs) Identification:

Sr. SOP Description / Title SOP No. Identified By

No. (Sign / Date)
Please furnish the

Operational
01 Operation of Air Compressor
Manual of

machine

Please furnish

Operational

02 Preventive maintenance of Air Compressor manual of

machine to

customer
 Chicago Pneumatic Compressors

INSTALLATION QUALIFICATION
Equipment / System Compressed Air System
Document No. CP/IQ/ACME/002 Effective Date
Supersedes None Page Number 23 of 28

Comments: _____________________________________________________

_________________________________________________

__________________________________________________

Name Signature Date

Verified By

7.10 Manufacturer’s Certification and Reference Documents

Review and attach the manufacturer's certificate(s) and reference document(s) listed
below. Also specify others, if any. (Note: Write ‘NA’ if the specified document /
certificate is not applicable for the particular equipment.)
Location of Documents
the reviewed and
Sr. Available
Details of document / certificate document / attached by
No. (Yes/ No)
certificate (Sign / Date)

1 Calibration certificate(s). YES

 Chicago Pneumatic Compressors

INSTALLATION QUALIFICATION
Equipment / System Compressed Air System
Document No. CP/IQ/ACME/002 Effective Date
Supersedes None Page Number 24 of 28

2 Material of Construction certificates YES

3 Equipment Manual(s) / Brochure(s) YES

4 Copy of Purchase Order YES

5
Other (it any)

Comments: _____________________________________________________

_________________________________________________

__________________________________________________

Name Signature Date

Verified By

7.11 Deficiency (if any) and Corrective Action Report

If there is no deficiency, then write NA
 Chicago Pneumatic Compressors

INSTALLATION QUALIFICATION
Equipment / System Compressed Air System
Document No. CP/IQ/ACME/002 Effective Date
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Description of deficiency and date observed:

_________________________________________________________________
________________________________________________________________________
__________________________________________________________
Agency / Person, responsible for corrective action and date assigned:
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________

Corrective actions taken and date conducted:

________________________________________________________________________
________________________________________________________________________
________________________________________________________________________
____________________________________________

Name Signature Date

Deficiency Reported
by
Corrective action
Conducted by
Checked and
certified by

8.0 Re-qualification
Installation Qualification to be re qualified on:
 Replacement of major component of the equipment with a new component.
 Any major modification in the existing equipment.
 Shifting / Reinstallation / Re commissioning of the equipment from one location to
another.
 Chicago Pneumatic Compressors

INSTALLATION QUALIFICATION
Equipment / System Compressed Air System
Document No. CP/IQ/ACME/002 Effective Date
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9.0 Final Report

9.1 Summary

Checks Observations Remarks

Whether Acceptance Criteria of the Yes/No
protocol and specific checkpoints are
met.

Comments: ___________________________________________________________
______________________________________________________
______________________________________________________

9.2 Conclusion:

The Compressed Air System bearing No IS qualifying the Installation Qualification test
as per the guideline described in this Protocol. The Compressed Air System can Be
tested for its operational qualification as per Protocol
 Chicago Pneumatic Compressors

INSTALLATION QUALIFICATION
Equipment / System Compressed Air System
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10.0 Report Approval

Reviewed By Signature Date

Approved By Signature Date

11.0 Appendix
11.1 Abbreviations

cGMP - Current Good Manufacturing Practices

IQ - Installation Qualification
Page No. - Page Number
P&ID - Piping and Instrumentation Diagram
SOP - Standard Operating Procedure
Sr. No. - Serial Number
EID - Equipment Identification number
 Chicago Pneumatic Compressors

INSTALLATION QUALIFICATION
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11.2 Annexure

Sr.No. Annexure Details Annexure Number