EQUIPMENT QUALIFICATION

QUALIFICATION OF AIR Page 1 of 14

COMPRESSOR

Machine Description:  PACKAGE SL75‐AC
EQUIPMENT QUALIFICATION

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QUALIFICATION OF AIR
COMPRESSOR

CONTENTS:

1. Checklist for inspection of air Compressor

2. Design Qualification

3. Installation Qualification

4. Operational Qualification

5. Performance Qualification

6. Handover Certificate
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QUALIFICATION OF AIR
COMPRESSOR

CHECKLIST FOR INSPECTION OF AIR COMPRESSOR

Sr. Item Acceptance Criteria Qty. Observation

No.
1. Compressor Rotary Air compressor – 1 ISO 1217 : Annex C
Model PACKAGE SL75-AC,
Testing Standard – ISO
1217 Annex C, ISO 9300

2. Motor for 75 KW 2 POLE TEFC 1 Motor is designed and

compressor. MOTOR, VFD tested in accordance with
IEC 60034-2-1 testing
protocol. Test Report
held at supplier’s file.
3. Inter cooler 30 PSI Nominal Operating 1 No leakage under
Pressure, 50 PSI Maximum hydrostatic pressure – 75
Operating Pressure, 75 PSI PSI. Test Report held at
Hydrostatic Test supplier’s file.
4. Moisture separator Moisture separator with 1 Moisture separator with
drain valve. Pipe condensate solenoid
Connections :- Inlet Port 2" valves. This component
NPT is assessed in
Outlet Port 2" NPT accordance with pressure
Drain 1/2" NPT. equipment directive
(97/23/EC). Refer
Manual.

5. After cooler 150 PSI Nominal Operating 1 No leakage under

Pressure, 165 PSI hydrostatic pressure –
Maximum Operating 250 PSI. Test Report
Pressure, 250 PSI held at supplier’s file.
Hydrostatic Test
6. Oil Cooler 30 PSI Nominal Operating 1 No leakage under
Pressure, 50 PSI Maximum hydrostatic pressure – 75
Operating Pressure, 75 PSI PSI. Test Report held at
Hydrostatic Test supplier’s file.
7. Safety interlocks Inbuilt safety interlocks built 1 Inbuilt safety interlocks
into compressor control are available and
panel for Alarms and Trips monitored in the control
panel. Refer O&M
Manual.
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QUALIFICATION OF AIR
COMPRESSOR

8. Control panel Control panel should have 1 As per Manufacturer’s

switches for ON & OFF. standards. Refer O&M
Manual.
9. Microprocessor Microprocessor with all The compressor includes
units: 1 a microprocessor based
Power unit control module, which
Processor module provides for starting,
Make: IR variable speed control,
pressure control,
operating control and
safety control of the unit.
Refer O&M Manual.

Checked By: Siddharth Patel

Date:08/08/2014
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QUALIFICATION OF AIR
COMPRESSOR

INSTALLATION QUALIFICATION

1. Purpose:
The purpose of Installation Qualification is to establish that the equipment and components
are as per the specifications, are checked, calibrated and are installed as per the approved
design.

2. Critical variables to be meet:

Critical variables to be met Acceptance criteria Observation Checked By

1. Services to be provided

1.1 Cooling media for Air to air cooler OK

compressor.

1.2 Electrical supply (Check
the electrical supply
required)
2. Installation of main unit
a. Voltage: 415 volts. (+/- Voltage : 415 V
10%)
b. Phases: 3 Phase
c. Frequency: 50 Hz

2.1 A process and instrument All instrument and components As per P&ID
diagram (P and ID) should are to be installed as per P and attached.
be available. ID. 39898960
2.2 Calibration of temperature All instruments should be As per
and pressure transmitters. calibrated as per respective SOP Manufacturer’s
global standards
2.3 Main unit assembly. a. The entire assembly of Entire package is
compressor, after cooler, mounted on a
inter cooler and motor shall common skid
be mounted on a common and enclosed in a
mild steel stand to form a sound
compact lay out (skid accentuated
mounted). enclosure
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QUALIFICATION OF AIR
COMPRESSOR

Critical variables to be Acceptance criteria Observation Checked

met By

2.4 Compressor and motor a. Compressor and motor should be The motor and
alignment. properly fixed on a fabricated MS air end are
structure integrally
b. Alignment of compressor and mounted. This
motor should be checked. assembly is
isolated from the
base by rubber
isolation mounts.
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QUALIFICATION OF AIR
COMPRESSOR

3. Safety points
Critical variables to be Acceptance criteria Observation
met
3.1 Earthing strips a. The material used should Available
be Galvanized Iron.
b. For mechanical strength the
strip should not have a
cross sectional area less
than 25 mm X 3 mm.
The continuity strip on the
various floors and staging
should be connected together
with two or more similar
conducting strips, which
connect to the main earth point
in the building.
3.2 Equipment safety The controller offers When a warning occurs, the
interlock switches. feedback to the operator display will alternate between
via display points, warning the current message and the
and/or alarm points and warning message. The
adjustable operating following is a list of the
parameters. warning messages in
equipment safety interlock
features. Refer O&M for
further details.
TEMPERATURE SENSOR FAIL
HIGH TEMPERATURE
1st. stage discharge temperature
2nd. stage inlet temperature
2nd. stage discharge temperature
Bearing oil temperature
PRESSURE SENSOR FAIL
MOTOR OVERLOAD
CALIBRATION FAIL
EMERGENCY STOP
NO CONTROL POWER
LOW OIL PRESSURE.
HIGH CONDENSATE LEVEL
3.4 Microprocessor a. It should be enclosed in a Available as a part of the
panel. electrical panel
b. Instruction manual should be
provided.
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COMPRESSOR

3. References:
Refer O&M Manual - 80441272

4. Documents to be attached:
Refer O&M Manual - 80441272

5. Any changes made against the formally agreed parameters.

No.

6. Review (Inclusive of follow up action, if any):

Not Required.

7. Recommendations:
As per O&M Manual - 80441272

8. Installation qualification signing off:

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QUALIFICATION OF AIR
COMPRESSOR

OPERATION QUALIFICATION

1. Purpose:
The purpose of operational Qualification is to establish that individual components and
machine i.e. the entire system as a whole is functioning as specified.

2. Critical variables to be met:

Critical variables to be met Acceptance criteria Observation

1. Check functioning of all a. All sensors should be functional. Noted

parameters.
2. Start the air compressor a. Air compressor should start and Noted
as per SOP/manual. be operational.
3. Check the direction of a. Direction of rotation should be Noted
rotation of the as specified.
compressor drive
system.
4. Check the compressor a. Should not be more than 10 kg/ Noted
discharge pressure. cmg2.
5. Check the compressor a. Should not be less than 2.3 barg As per design standards.
oil pressure. and more than 3.2 barg.
6. Check each safety and a. Each safety and panel Noted and as per design
Microprocessor Parameters should be standards
Parameters functional.
7. Check the loading a. Loading-unloading should be at Set as per demand
unloading. Set value. requirements and in line
with the design standards
operating in a band of 1
psig
8. Check the safety a. Compressor should trip at low Alarms are inline to the
interlock switches oil pressure 2.3 barg and design standards
operation indicating the fault on applicable for rotary
Microprocessor screen. screw compressors
Bearing Oil Low Pressure
Bearing Oil High
Temperature
Bearing Oil High Pressure
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3. References: (if any)

Refer O&M Manual - 80441272

4. Documents to be attached:
Refer O&M Manual - 80441272

5. Any changes made against the formally agreed parameters.

No.

6. Review (Inclusive of follow up action, if any):

Not Required.

7. Recommendations:
As per O&M Manual - 80441272

8. Operational qualification signing off:

Priyank Gandhi/Siddharth Patel
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QUALIFICATION OF AIR
COMPRESSOR

PERFORMANCE QUALIFICATION

1. Purpose:
The purpose of Performance Qualification is to confirm that the Air compressor is capable of
producing required moisture, oil free compressed air and is capable of consistently
performing as it is purposed to perform.

2. Critical variables to be met:

Check the following parameters of Air compressor and monitor it during performance test of
compressor package.

Critical variables to be met Acceptance criteria Observation

1. Check the discharge It should not be more than 7 barg .

pressure of
compressor
2. Check the oil pressure.
3. Loading-unloading
4. Check the oil traces
through discharge air.
5. Microprocessor
checks
It should be 2.3 to 3.2 barg
It should be at set value.
Should not be traceable. Qualifies for
Class 0 Air quality
standards.
Programmable operation As per
a. Check performance of key to enter manufacturer
system. standards
b. Check performance of key to reset applicable
system.
c. Check performance of key to observe
last fault.
d. Check performance of key for running
Hours.
e. Check performance of key for display
f. Check the performance of “Dtls” key for
information of tripping.
g. Check the performance of “system details
’’ key for display system details.
h. Check the performance of “Maint.
Schedule” key for display information
about compressor maintenance
i. Check the performance of “Timer” key to
set & display timer status.
j. Check the performance of “Run Hours”
key to display running time of compressor.
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Critical variables to be Acceptance criteria Observation

met
Contd... k. Check the performance of “Load Unload”
key to unload compressor manually.
l. Check the of performance programmable
auto loading and unloading.

3. References: (if any)

Refer O&M Manual - 80441272

4. Documents to be attached:
Refer O&M Manual - 80441272
Performance Test Report of Compressor Package

5. Any changes made against the formally agreed parameters.

No

6. Review (Inclusive of follow up action, if any):

Not Required.

7. Recommendations:
As per O&M Manual - 80441272

8. Performance qualification signing off:

Priyank Gandhi/Siddharth Patel
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QUALIFICATION OF AIR
COMPRESSOR

DESIGN QUALIFICATION

1. Purpose:
The purpose of Design Qualification is to confirm that the Air compressor is designed &
validated of delivering required oil free compressed air consistently.

3. Critical variables to be met:

The following parameters of air compressor have been considered for the design of the
compressor:

Model SL75 (Air cooled)

Delivered Capacity (FAD) 442 CFM
Nos. of Stages TWO STAGE
Compressor Operating Pressure 7 BAR(G)
Driver Rating / Nominal Motor Power 75 KW
Shaft Power @ 7 Barg 81 kW
Cooling Fan Nominal Power 4 KW (for Air Cooled)
Compressor Operating Pressure Range 5 to 7 BAR(G)
Cooling System Air Cooled
Electrical Requirements 415+3 %, 50Hz
Starter up With Separate/Stand Alone VFD
Sound Level 76 dB(A) (+/-3)
After Cooler CTD 14 Deg C (Air Cooled)
Main Drive Motor Type Induction Motor, TEFC, IP55
Design Ambient Temperature 46 Deg C
• Note: FAD (Free Air Delivery) is actual flow rate at the compressor inlet measured at the discharge terminal 
point of the package in accordance with ISO1217 Annex C.  
• Sound levels are "free field conditions" per CAGI/Pneurop, ±3 dB(A) 
• Ingersoll‐Rand compressors are not designed, intended or approved for breathing air applications. 
Ingersoll‐Rand does not approve specialized equipment for breathing air applications and assumes no 
responsibility or liability for compressors used for breathing air service. 

3. References: (if any)

Refer GA/P&ID drawings
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COMPRESSOR

4. Documents to be attached:
None

5. Any changes made against the formally agreed parameters.

No

6. Review (Inclusive of follow up action, if any):

Not Required.

7. Recommendations:
None

8. Design qualification signing off:

Hitesh Patel/Chintan Vazda