HVAC-001 Hot Water Generation Commissioning Test Protocol - Vera

Hot Water Generation - HVAC
Commissioning Test Protocol
Shimizu Corporation India Pvt Ltd

Shimizu Detailed Design
CP-HWG-035-001, Issue: A
CP-HWG-035-001, Version A
Date – 20/11/2017
COMMISSIONG TEST PROTOCOL & REPORT

System : Hot Water Generation - HVAC
GlaxoSmithKline Equipment ID : HWG/035/001 Shimizu

Pharmaceuticals Corporation India
Pvt Ltd
Date : 20-Nov-2017
Document No. : CP-HWG-035-001
Version :A
The following signature indicates that the commissioning test protocol has been released for execution.
Name Organization Department Signature Date
Prepared by
Reviewed by
Approved by
Page 2 of 59
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The following signature indicates that the commissioning test protocol has been executed and reported.
Name Organization Department Signature Date
Checked by
Approved by
Page 3 of 59
Date – 20/11/2017
Contents
1 Reference Documents 6
1.1 Verification with as built P&ID 6
2 Version History 6
3 Introduction & Scope 7
4 Purpose 7
5 System Description 7
6 System Boundaries 8
7 Testing Rationale 8
8 List of Execution Personnel 8
9 Deviation List 8
10 Acceptance Criteria Summary 9

10.1 Pre-commissioning checklist 9
10.2 Documentation 9
10.3 Installation 9
10.4 Operational 10
10.5 Additional 10
11 Test Sheets 11
Documentation – Pre-Requisite Documentation Review 12
Installation Verification – Hot Water Generation Skid 14
Documentation - Calibration Verification Record (General) 23
Installation Verification (System) - Utilities 25
Safety- Zero Access Machinery Guarding & Lock-Out/Tag-Out (LOTO)
Testing & Verification Requirements 26
Control Verification – HMI Functionality (General/Commissioning) 30
Control Verification - Password Access (General) 34
Alarm and Interlock Verification - General 36
COMMISSIONING REPORT 39
Performance Verification – Flow, Pressure & Temperature Verification Test 44
Control Verification – Control Inputs and Output Record (Functional) 48
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Support - Training Verification 53

Support - Test Equipment Record 55
Support - Signature Record 57
12 List of Attachments 59
13 Exclusion 59
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1 Reference Documents
Ref. Document No. Document Title

1 IN5010049-42-SP-0003_D_01 Specification for Hot Water Generation
2 IN5010049-41-CA-0014_C_01 HVAC Hot Water Line Sizing and Pressure Drop Calculation
3 IOM GSK HWS -HVAC IOM of Hot Water System - HVAC
4 TS3AQ4_Analog Output Card Analog Output Card Data Sheet
5 TM3AI8-Analog Input card Analog Input Card Data Sheet
6 Rittal_TS8 Panel Catalogue
7 Modicon_Easy_M200_TM200CE24R TM200CE24R controller
8 HMI-GXU5512 HMI-GXU5512 catalogue
9 Cable Megger Test
10 A174209C-1-HR Pipe Leak Test (Hydro)
11 System Walkdown
12 Pipe Flushing Report
1.1 Verification with as built P&ID

Ref. Document No. Document Title
13 PID-00-0-MLGHW-HVAC-Model Hot Water Generation – HVAC P&ID
14 D85519-HVAC-ELP Hot Water System – HVAC GA
2 Version History
Date Version Revised By Reason for Revision

(dd-mm-yyyy)
20-Nov-17 A Chong Initial Issue
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3 Introduction & Scope

This document records the commissioning of the hot water generation for HVAC as Approved
Design Specification. These systems have been assessed and have been categorised as Indirect
Impact. Indirect systems shall be subject to commissioning.
4 Purpose
The purpose of this document is to provide documented evidence that the components of the hot
water generation for HVAC are installed correctly and in accordance with the requirements of
design documentation, that supporting documentation is in place and to provide evidence of the
systems proper operation.
5 System Description
Hot Water Generation – HVAC (18.5 m3/hr)
System Equipment Description Qty Design Parameters
Make: Armstrong
Model: D85180
Capacity:100 L
Hot Water Expansion Tank with Pressurizing
1 No
pumps Design Temperature: 120⁰C
Design Pressure: 5 barg / Full
Vacuum
MOC: SS316L
Make: Grundfos
Model: CR15-04 A-F-A-E-HQQE
Rated Speed: 2917 RPM
Rated flow: 17m3/h
Hot Water Hot Water Centrifugal pumps VFD based 4 Nos
Generation Rated head: 44.8m
@ 50⁰C Rated power: 4 kW
Mains frequency: 50 Hz
Quantity: 4
Make: Alfa Laval
Model: M6 MFM
Plate Heat Exchanger 1 No
Design Pressure:
Design Temperature:
Make: Armstrong
Air separator 1 No Model: Air Sep 2-1/2 NPT Vortex
MOC: Cast Iron
Make: Armstrong
Double Duty Pump Trap 1 No
Model: DD6 1-1/2’’ X 1’’ 150RF
Control Panel w/ PLC
Page 7 of 59
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6 System Boundaries
As per system boundary as per mark up on P&ID drawing no PID-00-0-MLGHW-HVAC-Model.
7 Testing Rationale
Testing described within this report/protocol is based upon the Commissioning Plan. All
acceptance criteria will be verified for indirect systems.
8 List of Execution Personnel

The following personnel(s) are trained and approved to carry out the commissioning test protocol.
Ref. Name Organization Designation Signature Date

1
10
11
12
13
14
15
9 Deviation List
Record each of the deviations raised during the completion of the protocol and the date that the
deviation was resolved.
Deviation Deviation Description Date Resolved Initial and

Ref. (dd-mm-yyyy) Date
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Deviation Deviation Description Date Resolved Initial and

Ref. (dd-mm-yyyy) Date
10 Acceptance Criteria Summary

This section, detailing system specific Acceptance Criteria (A/C), should be completed following a
review of the test sheets, within Section 11, and supporting data
10.1 Pre-commissioning checklist
A/C. Acceptance Criteria A/C Met? Test Sheet Reference Initial

Ref. Yes/No (If any) Date/Sign
The pre-commissioning checklist of hot water Annexure 1_Pre-

1 generation system (HVAC) has been commissioning checklist
completed satisfactorily.
10.2 Documentation
A/C. Acceptance Criteria A/C Met? Test Sheet Reference Initial

Ref. Yes/No (If any) Date/Sign
Operation and maintenance documentation is O&M shall be provided part of

2 available to enable proper operation and dossier.
maintenance of the system
Devices have been calibrated in compliance 0066_Documentation -

3 with the Device Assessment and have valid Calibration Verification Record
calibration certificates (General)
10.3 Installation
A/C. Acceptance Criteria A/C Met? Test Sheet Reference Initial and
Ref. Yes/No (If any) Date
The installation has been verified as correct 0011_ Installation Verification

4 against the design drawings, – Hot Water Generation Skid
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System specified installation checks have 0011_ Installation Verification

5 been completed. – Hot Water Generation Skid
Hardware installation meets the design 0058_ Control Verification –

6 specification and software versions and HMI Functionality
configurable parameters have been recorded. (General/Commissioning)
10.4 Operational
Alarms and interlocks operate to design 0055_Alarm and Interlock

7
specification Verification – General
The system performance meets design HWG/001_1_Commissioning

specification Report
8
Annexure 2_Pump
commissioning report
10.5 Additional
Test Instrumentation used during completion 0006_ Support – Test

of the test protocol was in calibration at the Equipment Record
9
time of testing and the calibration certification
is referenced.
The signature register has been completed 0009_ Support – Signature

10 by those involved in the commissioning Record
activities and training records are available.
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11 Test Sheets
This section details the checks to be carried out in support of the system specific acceptance
criteria contained within Section 11.
Test Sheet Title Test Sheet Ref.
Pre-Commissioning Checklist Annexure 1
Documentation - Pre-Requisite Documentation Review 0013
Installation Verification – Hot Water Generation Skid 0011
Documentation - Calibration Verification Record (General) 0066

Installation Verification (System) – Utilities 0010
Safety- Zero Access Machinery Guarding & Lock-Out/Tag-Out (LOTO) Testing
0044
& Verification Requirements
Control Verification – HMI Functionality (General/Commissioning) 0058
Control Verification - Password Access (General) 0057
Alarm and Interlock Verification – General 0055
Commissioning Report HWG/001_1
Pump Commissioning Report Annexure 2
Performance Verification – Flow, Pressure & Temperature Verification Test HWG/001_2

Control Verification – Control Inputs and Outputs Record (Functional) 0525
Support – Training Verification 0007
Support – Test Equipment Record 0006
Support – Signature Record 0009
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Title: Documentation – Pre-Requisite Documentation Review Reference: 0013

Objective:
1 To provide evidence that required pre-requisite commissioning/qualification stages (which must be completed prior to starting testing
within this protocol) have been completed, referenced and the approval status documented. This verification will include the
commissioning or qualification of required supporting facilities, utilities or equipment.
Pre-requisites: None
Method:
1 Record the document reference, version and approval status (conditionally approved or unconditionally approved) of each of the required
pre-requisite documents identified in the results table below.
Acceptance Criteria:
1 The required pre-requisite commissioning/qualification stages have been completed, referenced and the approval status documented,
unresolved snags/deviations do not impact upon the testing within this protocol.
Results:
Document Title Document Reference: Version Approval Status
Specification for Hot Water Generation IN5010049-42-SP-0003_D_01

HVAC Hot Water Line Sizing and Pressure Drop Calculation IN5010049-41-CA-0014_C_01
IOM of Hot Water System – HVAC IOM GSK HWS -HVAC IOM GSK HWS -HVAC
Analog Output Card Data Sheet TS3AQ4_Analog Output Card TS3AQ4_Analog Output Card
Analog Input Card Data Sheet TM3AI8-Analog Input card TM3AI8-Analog Input card
Panel Catalogue Rittal_TS8 Rittal_TS8
TM200CE24R controller Modicon_Easy_M200_TM200
CE24R
HMI-GXU5512 catalogue HMI-GXU5512
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Title: Documentation – Pre-Requisite Documentation Review Reference: 0013

Cable Megger Test
Pipe Leak Test (Hydro) A174209C-1-HR
System Walkdown Report
Hot Water Generation – HVAC P&ID PID-00-0-MLGHW-HVAC-
Model
Hot Water System – HVAC GA drawing D85519-HVAC-ELP
Comments/Deviations/Supporting Documentation:
Overall Test Outcome (PASS/FAIL) Tested By (Signature): Verified By (Signature): Date (dd/mm/yyyy):
Page 13 of 59
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Title: Installation Verification – Hot Water Generation Skid Reference: 0011

Objective:
1 To provide documented evidence that the installation of the hot water skid components is in accordance with the approved design
intentions, that the manufacturer’s recommendations have been considered, adequate access for maintenance is available.
Method:
1 Verify the components of hot water skid as identified within the results section below.
1 The hot water skid components have been correctly installed to the manufactures recommendations with adequate maintenance access
and are correctly tagged.
Results:
TAG ID Components Design Description Actual Result
Make: Armstrong
Model: D85180
Hot Water Expansion
Capacity:100 L
EV/035/001 Tank with Pressurizing
Pumps Design Temperature: 120⁰C
Design Pressure: 5 barg / Full Vacuum
MOC: SS316L
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Make: Grundfos
Model: CR15-04 A-F-A-E-HQQE
CP/035/001 Rated Speed: 2917 RPM
CP/035/002 Hot Water Centrifugal Rated flow: 17m3/h
CP/035/003 Pump VFD Based Rated head: 44.8m
CP/035/004 Rated power: 4 kW
Mains frequency: 50 Hz
Quantity: 4
Make: Alfa Laval
Model: M6 MFM
HE/035/001 Plate Heat Exchanger
Design Pressure: 10.50 kg/cm2
Quantity: 1
Make: Armstrong
Model: Air Sep 2-1/2 NPT Vortex
AS/035/001 Air Separator
MOC: Cast Iron
Quantity: 1
Make: Armstrong
SPT/035/001 Double Duty Pump Trap Model: DD6 1-1/2’’ X 1’’ 150RF
Quantity: 1
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PIT/035/001 Make: ABB
PIT/035/002 Model: 2600T
PIT/035/003 Measuring Range: 0-10 barg
PIT/035/004 Quantity: 8
Pressure Transmitter
PIT/035/005
PIT/035/006
PIT/035/007
PIT/035/008
Make: Kains
PG/035/001 Pressure Gauge
Range: 0 to 6 kg/cm2
PG/035/002 (Local)
Quantity: 2
Make: ABB
Model: RTD PT100
TIT/035/001
Max Pressure: 15 barg
TIT/035/002 Temperature Sensor
Operating Temp: 0-250⁰C
TIT/035/003
Output Signal: 4-20 mA
Quantity: 3
Make: Armstrong
Model: Accelabar 2-1/2 150 RF AFS 2-1/2 SC40
150 CS 305 4500 MM H20 HYDRO
FM/035/001 Flow Meter Operating Temp: 0-200⁰C
Operating Pressure: 0-10 barg
Operating flow rate: 0-6000 kg/hr
Quantity: 1
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Make: Armstrong
STR/035/006 Strainer Model: Strainer 2 150 RF ¾ NPT BD
Quantity: 1
STR/035/001 Make: Armstrong
STR/035/002 Model: Strainer 3 150RF CS WCB ¾ NPT BD
Strainer
STR/035/003 Quantity: 4
STR/035/004
Make: Armstrong
STR/035/005 Strainer Model: Strainer G 1-1/2 SW
Quantity: 1
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VBF/035/001 Make: Crane
VBF/035/002 Model: D85156
VBF/035/003 MOC: ASTM A276
VBF/035/004 Quantity:21
VBF/035/005
VBF/035/006
VBF/035/007
VBF/035/008
VBF/035/009
VBF/035/010
VBF/035/011 Butterfly valve (65NB)
VBF/035/012
VBF/035/013
VBF/035/014
VBF/035/015
VBF/035/016
VBF/035/017
VBF/035/018
VBF/035/019
VBF/035/020
VBF/035/021
Make: Expert Engineering Enterprises

Non Slam Check Valve
VNR/035/008 MOC: ASTM 351
(15NB)
Quantity: 1
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Make: Sant
VNR/035/006 Forged Steel Horizontal
VNR/035/007 Check Valve (40NB) MOC: ASTM A351
Quantity: 2
VNR/035/001 Make: Weir BDK Valve
VNR/035/002
Swing Check Valve MOC: ASTM A351
VNR/035/003
(65NB) Quantity: 5
VNR/035/004
VNR/035/005
Make: Armstrong
Model: ASTM PSTN 1-1/2’’ SW
VP/035/001 Piston Valve (40NB)
MOC: ASTM A105
Quantity: 1
Make: Armstrong
Model: Valve PSTN 1
VP/035/002 Piston Valve (25NB)
MOC: ASTM A105
Quantity: 1
VP/035/003 Make: Armstrong
VP/035/004 Model: Valve ASTM PSTN ½’’ SW
VP/035/005 Piston Valve (15NB) MOC: ASTM A105
VP/035/006 Quantity: 5
VP/035/007
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Make: L&T Valves Ltd.

Model: L7RSWC
VB/035/007 Ball Valve (25NB)
MOC: ASTM A216
Quantity: 1
Make: L&T Valves Ltd.
Model: L7FSWS
MOC: ASTM A105
Quantity: 1
VB/035/001 Make: L&T Valves Ltd.
VB/035/002
Model: LAFSWC
VB/035/003
MOC: ASTM A105
VB/035/005 Quantity: 7
VB/035/008
VB/035/009
Make: Darling Muesco

VPS/035/001 Safety Relief Valve
VPS/035/002 (25NB) MOC: Cast Steel
Quantity: 2
Make: Armstrong
Model: D657400
VPR/035/002 Control Valve (40NB)
MOC: ASTM A351
Quantity: 1
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Make: Mahavas Precision Controls

Pressure Regulating
VPR/035/001 MOC: Bronze / Gun Metal
Valve (25NB)
Quantity: 1
Make: Bell-O-Seal Valves
Bellow seal valve
VP/035/008 MOC: ASTM A216
(50NB)
Quantity: 1
PO/035/001 Quantity: 8
PO/035/002
PO/035/003
PO/035/004 P/T Port
PO/035/005
PO/035/006
PO/035/007
PO/035/008
Make: Armstrong
Model: Ib2011C 5/32
ST/035/001 Steam Trap
MOC; ASTM A351
Quantity: 1
Make: Armstrong
SM/035/001 Moisture Separator Model: DS-4 2 150RF
Quantity: 1
N/A Pipe MOC: ASTM A106 GR.B
N/A Pipe Insulation MOC: Rockwool and aluminium cladding
Control Panel & PLC + Bill of Material is same as per drawing no.:
CP-01
HMI + drive D88519-ELP
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Test Equipment Reference:

Overall Test Outcome (PASS/FAIL) Tested By (Signature): Verified By (Signature): Date (dd/mmm/yy):
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Title: Documentation - Calibration Verification Record (General) Reference: 0066

Objective:
1 To provide documented evidence that critical and non-critical instruments within the system have been calibrated to the required tolerance
across the required range.
Method:
1 Review the calibration certification available for each of the critical and non-critical instruments; to verify the calibrated tolerance and range
against the tolerance and range required for the routine process or operation. Record the calibration certificate reference, and next
calibration due date or calibration schedule reference.
1 Critical instruments have been calibrated and their tolerance and calibrated range meet the process or operation requirements.
Results:
Inst Ref Instrument Description Process / Operation Requirement Calibration Calibration Due
Certificate Date or
Tolerance Range Reference Calibration
Schedule Ref.
PIT/035/001 Pressure Transmitter ±0.06% 0-10 barg
TIT/035/001 Pressure Gauge ±1.5% 0-6 kg/cm2
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Title: Documentation - Calibration Verification Record (General) Reference: 0066

TIT/035/002 Pressure Gauge ±1.5% 0-6 kg/cm2
TIT/035/001 Temperature Sensor ±0.15⁰C 0-250⁰C
FM/035/001 Flow Meter ±0.05% 0-6000kg/hr
Page 24 of 59
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Title: Installation Verification (System) - Utilities Reference: 0010

Objective:
1 To provide documented evidence that the installation of utility supplies required for operation of the system are in conformance with the
design specification.
Method:
1 Verify the installation of each of the required utilities, identified within the results section, recording the actual value(s).
1 The required utility supplies are installed in conformance with the design specification.
Results:
Utility Design Actual Initial/Date
Electricity 415V±10% 3 phase/50 Hz ±5%
Steam 3-3.5 barg
Compressed air 6-7 barg
Make up water 2-3 barg

Overall Test Outcome (PASS/FAIL): Tested By (Signature): Verified By (Signature): Date (dd/mmm/yy):
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Title: Safety- Zero Access Machinery Guarding & Lock-Out/Tag-Out (LOTO) Testing & Verification Reference: 0044
Requirements
Objective:
1. To provide documented evidence that the machinery physical guarding and lock-out/tag-out (LOTO) requirements have been designed,
installed and tested safely, to prevent contact with dangerous parts and prevent injury during normal operation or during an intervention, as
defined in Global Engineering Standard - Machinery Safety - GES 110.
Note:
1) Zero Access is a standard of machine guarding where it is physically impossible for anyone to gain access to any dangerous parts of a
machine or equipment without using a tool to remove or disable a safeguard.
2) Lock-out/tag-out (LOTO) is the required standard within GES 110 to ensure that machinery remains isolated from all sources of energy during
an intervention to protect those involved from being injured either by energy sources or unexpected operation of equipment.
Pre-requisites: Global EHS Standard 604 – Use of Work Equipment Assessment completed.
Method:
1. Complete the required checks to assess the equipment against the defined criteria detailed within the results section. Where applicable
checks should be completed with the equipment in normal run mode. If criteria are not met ensure details are recorded.
Note: All tests are to be completed safely and in compliance with site operating & safety procedures.
1. Machinery physical guarding and lock-out/tag-out (LOTO) requirements have been designed, installed and tested safely, to prevent
contact with dangerous parts and prevent injury during normal operation or during an intervention, as defined in Global Engineering Standard -
Machinery Safety - GES 110.
Results:
Physical Guarding Testing

Criteria Criteria Met? Comments
(Yes/No or
N/A)
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Requirements
Guards prevent personal access to all dangerous parts.
All guards are secured in place via interlock or require a tool

to remove them.
Equipment motion stops on opening of each interlocked
guard.
Equipment does not start when each interlocked guard is
closed after intervention.
Equipment starts when reset & restarted from the control
panel.
Unguarded/uncovered hazards are out of reach at a height of
at least 2.7m.
Safety fences or barriers fixed around equipment are at least
1.6m high.
Gaps under safety fences or barriers are less than 180mm, to
prevent person access
Gaps adjacent to moving parts (nip points) should be less
than 2mm, or guarding should be in place to prevent access.
Page 27 of 59
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Requirements
If apertures in guarding are capable of:

a) Finger-tip entry (gap up to 6mm) then the hazards must be
greater than 10mm away
b) Finger access (gaps between 6mm and 12mm) then the
hazards must be greater than 100mm away.
c) Hand access (gaps between 12mm and 20mm*) then
d) Arm entry (gaps between 20mm* and 120mm) then the
*Note: For round or square openings, the 20mm limit on
opening size to prevent arm entry can be safely increased to
30mm.
Where parts come together there is a risk of crushing. The
gap should be:
a) Greater than 25mm where there is finger access to prevent
finger crushing
b) Greater than 100mm where there is hand access to prevent
hand crushing
c) Greater than 180mm where there is arm/leg access to
prevent arm/leg crushing
d) Greater than 500mm where there is body access to prevent
body crushing
Scissor type shear hazards should be prevented by ensuring
that gap between the moving parts is less than 4mm or
greater than 120mm or guarding must be in place to prevent
access.
Lock-Out/Tag-Out (LOTO) Testing
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Requirements
List all equipment energy sources.
Criteria Criteria Met? Comments

(Yes/No or
N/A)
Are all appropriate warning signs in a visible position where
energy or stored energy is present (e.g. electrical, thermal,
crushing, etc)?
Are all isolation points for hazardous energy are clearly
identified and labelled?
Can all isolation points be locked in their isolated position?
Are all isolation points clearly identified for their state of

isolation (e.g. ON/OFF, OPEN/CLOSED, etc)?
Are all isolation points easily accessible?
Overall Test Outcome (PASS/FAIL): Tested By (Signature): Verified By (Signature): Date (dd/mm/yyyy):
Page 29 of 59
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Title: Control Verification – HMI Functionality (General/Commissioning) Reference: 0058

Objective:
1 To provide documented evidence that Human Machine Interface (HMI) panel conforms to and functions according to the provided HMI
graphic and functional specification.
Pre-requisites:
1 System HMI screens and functions has been approved as per GSK requirement.
Method:
1 The system HMI will be challenged using the system user manual and screenshots below.
1 All HMI screens and the methods used to navigate from screen to screen are as described below and in the operating manual.
Results:
Step Test Method Expected Result Actual Result Initial / Date
1 Confirm HMI panel is as described HMI panel graphics should

as below and that the function of display as shown below. The
all features is mentioned as per function of all features is
below. known.
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Overall Test Outcome (PASS/FAIL): Tested By (Signature) Verified By (Signature): Date (dd/mm/yyyy):
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Title: Control Verification - Password Access (General) Reference: 0057
Objective/Purpose:
1 To provide documented evidence that the correct levels of password protection are installed, thus preventing unauthorised software
changes to be made.
Pre-requisites:
1 System control software version is current and controlled in accordance with GSK procedures and policies.
Method:
1 The system access will be challenged to ensure that operators and technicians only have access to those areas of the program which
have been agreed as required for the furtherance of their individual duties.
Note: The number of access levels are to be configured at the time of commissioning as per GSK requirements.
1 Each level of access has its own specific access criteria and operators with differing access authorities cannot enter program areas not
within their remit.
Results:
Step Test Method Acceptance Criteria Initial/ Date
1 Attempt to log onto system and run in normal Machine will not allow normal operation to be
operation using an incorrect password. performed without correct password.
2 Level 0 (Operator Level), login by using operator
View only. No other parameters can be changed.
username and password.
3 All parameters can be modified except configuration
Level 1 (Supervisor Level), login by using supervisor
of controller parameters, adjustment of timer, set
username and password.
parameters, PID settings and test mode activation.
4 Level 2 (Administrator Level), login by using
All parameters can be modified.
administrator username and password.
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Title: Control Verification - Password Access (General) Reference: 0057

Overall Test Outcome (Pass/Fail): Tested By (Signature): Verified By (Signature): Date (dd/mmm/yy):
Page 35 of 59
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Title: Alarm and Interlock Verification - General Reference: 0055

Objective:
1 To provide documented evidence that the alarms operate to the design specification.
Method:
1 Simulate conditions 5% beyond the design alarm set point. Note the actual value noted the time delay before alarm activation and the
action on alarm.
1 Alarm(s) and where applicable interlock(s) operate to design specification.
Results:
Alarm Ref Design Actual A/C Met?
(YES/NO)
Alarm Setpoint Action on Alarm Alarm Triggered Action on Alarm
Pressure Low Indication

Transmitter
Pressure High Indication
Transmitter
Temperature Low Indication
Transmitter
Temperature High Indication
Transmitter
Differential Low Indication
Pressure
Transmitter
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Differential High Indication

Pressure
Transmitter
Design interlock Result A/C Met?
(YES/NO)
Overload Protection of panel using over and Low -voltage/ over
current and single-phase failure protection relay.
Hot water overshoot protection using temperature sensor and

ON/OFF steam shutoff valve.
Fouling monitoring and PHE maintenance indication
Availability of diagnosis system
Data logging and report generation on the HMI for consumption of

steam and process liquid.
Note:
1. For process liquid consumption, with the availability of
water flow meter, flow rate can be logged.
2. For Steam Consumptions, with the availability of
pressure and temperature transmitter, steam flow rate
can be calculated with the help of water consumption
rate, Delta T, steam pressure and temperature.
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Overall Test Outcome (PASS/FAIL): Tested By (Signature): Verififed By (Signature): Date (dd/mmm/yy):
Page 38 of 59
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COMMISSIONING REPORT Reference: HWG/001_1
Client GLAXOSMITHKLINE PHARMACEUTICALS LIMITED
Contractor SHIMIZU CORPORATION INDIA PVT LTD

Project GSK ORAL SOLID DOSAGE FACILITY
Sub-Contractor ARMSTRONG
Equipment Supplier ARMSTRONG
Equipment ID HWG/035/001
Equipment Name Hot Water Portable Generation – HVAC
Location/Area PRODUCTION AREA
Date of Verification
VFD Commissioning Report
Panel No Incomer Motor Details Output Details Physical Parameter MODBUS Remarks
Voltage (Volts) Wiring Cross COMM Detail
Checked Verification
(YES/NO) Done
(YES/NO)
L1: Power: 4 kW Power: kW Address:
L2:
Voltage: 415 V AC Voltage: V
L3:
Current: 7.9 A Current: A
E-N:
Speed: 2917 RPM Speed: RPM
Frequency: 50 Hz Frequency: Hz
Page 39 of 59
Date – 20/11/2017

L2:
L3:
E-N:
L2:
L3:
E-N:
L2:
L3:
E-N:
Hot Water Generation Skid Commissioning Report
Sr. Procedure and Checkpoint Status Remarks

No
1 Switch on the power supply.

Once the panel is energized, actuator of the 3-way
2
valve gets actuated.
Open the top lid of the actuator to configure the
3
actuator
Page 40 of 59
Date – 20/11/2017
At least two buttons must be pressed simultaneously

4
to activate any control.
Press mode and set simultaneously to goggle
5 between remote or local mode. For Normal
operations select local mode only.
Press mode and up(+) button to select temperature
6
unit.
7 Press set and up(+) button to increase the set point.
Pressure set and down (-) button to decrease the set
8
point.
Record the desired set up by repeating either step 7
9
or 8.
For further instructions on the key pad refer to the
10
IOM of Emech valve section 6.0.
Open instrument air inlet valve and ensure air
11
pressure on AFR.
During start up use the makeup water pump
12
(secondary pump) to fill water in the system.
Once the water circuit is filled, we can turn off the
13 secondary pump and turn on the main recirculation
pump.
All these operations can be controlled through the
14
PLC.
Kindly put the desired set point through HMI for
15
discharge water pressure.
Pump will cut off when the desired pressure of water
16
is attained in the secondary side.
Page 41 of 59
Date – 20/11/2017
Ensure that the secondary side water flow

17
continuously at consistent pressure.
Open slowly the team inlet valve of the hot water
18
system.
19 Open the isolation valve of the upstream of the trap.
Open the isolation valve of the upstream of the
20
double duty pump.
Steam enters the heat exchanger and starts heating
21
the water instantaneously.
Condensate so formed gets separated through the
22 double duty pump and flows into the condensate
return line.
Put the PID tuning in AUTO mode so that the PID
23 starts tuning and the desired temperature is attained
in the system.
Now slowly open the inlet valve to complete open
24
condition.
One would observe the temperature in secondary
25 side of the water raising and fast approaching to set
point.
26 The system is now commissioned.
System would take some time to attain the
27
equilibrium and observe the system for some time.
Time taken by the system to reach the set point
28
mainly depends upon the system hold up volume.
Page 42 of 59
Date – 20/11/2017
Page 43 of 59
Date – 20/11/2017
Title: Performance Verification – Flow, Pressure & Temperature Verification Test Reference: HWG/001_2
Objective:
1 To verify the flow of hot water generation skid is at a consistent pressure.
2 To verify the pressure of the hot water generation skid is as per design specification.
3 To verify the outlet temperature of the hot water generation skid is as per design specification and time taken to achieve the setpoint
temperature.
Pre-requisites:
1 Hot water skid has been pre-commissioned.
Method:
1 Monitor the flow, pressure & temperature of the hot water generation skid for 2 hours with an interval of 30 minutes to ensure no pressure
& temperature drop.
1 Flow of hot water generation skid is at a consistent pressure of 18.5 m3/hr.
2 Temperature of the hot water is as per design specification.
Results:
Page 44 of 59
Date – 20/11/2017
Flow Verification Test

Flow Meter: FM/035/001 – 18.5 m3/hr
Time (hr)
30 60 90 120
Average
Remarks
flow Rate
Pressure Verification Test

Pressure Transmitter: PIT/035/001 – Water Side (4 barg)
Pressure Transmitter: PIT/035/008 – Steam Side (3.5 barg)
Time (hr)
30 60 90 120
Average
Remarks
Pressure
Page 45 of 59
Date – 20/11/2017
Temperature Verification Test

Temperature Transmitter: TIT/035/002 – Outlet (50⁰C)
Time (hr)
30 60 90 120
Average
Remarks
Temperature
Time taken to reach required setpoint
Page 46 of 59
Date – 20/11/2017
Page 47 of 59
Date – 20/11/2017
Title: Control Verification – Control Inputs and Output Record (Functional) Reference: 0525
Objective:
1 To ensure that the correct field devices are connected to the relevant Input and Output address of the PLC.
Pre-requisites:
1 System control software version is current and controlled in accordance with site and corporate procedures and policies.
Method:
1 To carry out this test refer to the PLC Input/output Schedule listed in IO document reference.
2 For each of the addresses given in the I/O schedule check that the device listed is correct against the module address reference.
1 The device connected to an address is as listed in the I/O schedule.
Note: Some addresses will have a function but will not have a physical device connected.
Results:
Mode of
I/O Description Card Model Field Device I/O Type I/O Count Actual Result
Checking
CPU-
Cycle Start N/A Visual DI I0
TM200CE24R
CPU-
Cycle Stop N/A Visual DI I1
TM200CE24R
Circulation
CPU-
Pump Main ON N/A Visual DI I2
TM200CE24R
feed back
Circulation Std.
CPU-
By ON feed N/A Visual DI I3
TM200CE24R
back
Page 48 of 59
Date – 20/11/2017
Makeup Pump
CPU-
Std. By ON feed N/A Visual DI I4
TM200CE24R
back
Makeup Pump
CPU-
Std, By ON N/A Visual DI I5
TM200CE24R
feedback
Circulation CPU-
Pump Main Trip N/A Visual DI I6
TM200CE24R
Circulation
CPU-
Pump Std. By N/A Visual DI I7
TM200CE24R
Trip
Makeup Pump CPU-
Main Trip N/A Visual DI I8
TM200CE24R
Makeup Pump CPU-

Std. By Trip N/A Visual DI I9
TM200CE24R
CPU-
Auto Selection N/A Visual DI I10
TM200CE24R
CPU-
Manual N/A Visual DI I11
TM200CE24R
Selection
CPU-
Phase Failure N/A Visual DI I12
TM200CE24R
Makeup Main
CPU-
Pump Auto ON N/A Visual DO Q0
TM200CE24R
Command
Page 49 of 59
Date – 20/11/2017
Makeup Stdby
CPU-
Pump Auto ON N/A Visual DO Q1
TM200CE24R
Command
Circ. Main Pump
CPU-
Auto ON N/A Visual DO Q2
TM200CE24R
Command
Circ. Standby
CPU-
Pump ON N/A Visual DO Q3
TM200CE24R
Command
Makeup Pump
CPU-
Pressure N/A Visual DO Q4
TM200CE24R
Healthy
Circulation
CPU-
Pump Pressure N/A Visual DO Q5
TM200CE24R
Healthy
Temperature
CPU-
Overshoot N/A Visual DO Q6
TM200CE24R
ON/OFF Valve
Tower Lamp CPU-
Red N/A Visual DO Q7
TM200CE24R
Tower Lamp CPU-

Amber N/A Visual DO Q8
TM200CE24R
CPU-
Hooter N/A Visual DO Q9
TM200CE24R
Page 50 of 59
Date – 20/11/2017
Make Up Water
Pressure
Pump Inlet TM3AI8 Visual AI I0+ / I0-
Transmitter
Pressure
Circulation Main
Pressure
Water Pump TM3AI8 Visual AI I1+ / I1-
Transmitter
Outlet Pressure
Make Up Pump Pressure
Outlet Pressure TM3AI8 Visual AI I2+ / I2-
Transmitter
Hot water return Pressure

line pressure TM3AI8 Visual AI I3+ / I3-
Transmitter
Cold water PHE Pressure

Inlet pressure TM3AI8 Visual AI I4+ / I4-
Transmitter
Circulation
Pressure
Standby Pump TM3AI8 Visual AI I5+ / I5-
Transmitter
Outlet Pressure
Hot water PHE Pressure
outlet pressure TM3AI8 Visual AI I6+ / I6-
Transmitter
Main Steam Inlet Pressure

Pressure TM3AI8 Visual AI I7+ / I7-
Transmitter
Hot water
Temperature
Return Line TM3AI8 Visual AI I0+ / I0-
Transmitter
Temperature
Hot Water PHE
Temperature
outlet TM3AI8 Visual AI I1+ / I1-
Transmitter
Temperature
Page 51 of 59
Date – 20/11/2017
Steam Inlet Temperature
Temperature TM3AI8 Visual AI I2+ / I2-
Transmitter
Hot Water Flow

to LGHW TM3AI8 Water Flow Meter Visual AI I3+ / I3-
Supply - DPT
Control Valve Differential
Set point TM3AQ4 Pressure Visual AO Q0+ / Q0-
Transmitter
Circulation
Pump VFD TM3AQ4 N/A Visual AO Q1+ / Q1-
Make Up Pump
VFD TM3AQ4 N/A Visual AO Q2+ / Q2-

Page 52 of 59
Date – 20/11/2017
Title: Support - Training Verification Reference: 0007

Objective:
1 To provide documented evidence that suitable training has been carried out to enable the correct operation and maintenance of the
equipment within the system.
Method:
1 Record the name of the trainees, a description of the training provided, the date training was completed and reference to the training
certification.
1 Required training has been completed and training records are available.
Results:
Name of Trainer Training Provided Date of Training Signature
(dd-mmm-yy)
Name of Trainee Description of Training Provided Date of Training Training Cert Ref
(dd-mmm-yy)
Page 53 of 59
Date – 20/11/2017
Title: Support - Training Verification Reference: 0007

Page 54 of 59
Date – 20/11/2017
Title: Support - Test Equipment Record Reference: 0006

Objective:
1 To provide documented evidence that that test instrumentation was in calibration at the time testing took place.
Method:
1 Record the reference, description, serial no, calibration due date, calibration frequency, calibration certificate no. and calibration certificate
location for each instrument used during completion of the protocol.
1 Test instrumentation was in calibration at the time of testing.
Results:
Test Inst Ref Test Instrument Description Instrument Calibration Calibration Calibration Calibration Initial/Date
Serial No Due Date Frequency Cert No Cert Location
Page 55 of 59
Date – 20/11/2017
Title: Support - Test Equipment Record Reference: 0006

Page 56 of 59
Date – 20/11/2017
Title: Support - Signature Record Reference: 0009

Objective:
1 To identify personnel involved in the completion of the protocol and provide documented evidence that appropriate training records are
available.
Method:
1 Each person involved in the completion of the protocol must enter their name, the name of the company they represent, sign and initial
the table below.
1 All personnel involved in the completion of this protocol are identified and have received appropriate training.
Results:
Name Company Signature Initial Training Record Ref
Page 57 of 59
Date – 20/11/2017
Title: Support - Signature Record Reference: 0009

Page 58 of 59
Date – 20/11/2017
12 List of Attachments
12. LIST OF ATTACHMENTS

No. Attachment Title Number of Pages
1 Annexure 1_Pre-commissioning checklist 3
2 Annexure 2_Pump commissioning report 3
3 Hot water system HVAC & Process FAT 1

MoM
4 Pump Test Report 12
5 Pump VFD Factory Test Certificates 4
6 Hot water system HVAC & Process 1

Inspection Offer Letter
7 Hot Water system HVAC & Process 17
Welding Procedures
8 Hot Water system HVAC Visual & 3
Dimension Inspection Report
9 Hot water system HVAC Hydrostatic Test 1
Certification
10 Hot Water System – HVAC P&ID 1
11 Hot Water System – HVAC Panel GA Drawing 34
& Power Circuit drawing
13 Exclusion
Page 59 of 59

HVAC-001 Hot Water Generation Commissioning Test Protocol - Vera

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HVAC-001 Hot Water Generation Commissioning Test Protocol - Vera

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Hot Water Generation - HVAC

Commissioning Test Protocol

Shimizu Corporation India Pvt Ltd

COMMISSIONG TEST PROTOCOL & REPORT

GlaxoSmithKline Equipment ID : HWG/035/001 Shimizu

Document No. : CP-HWG-035-001

Name Organization Department Signature Date

Name Organization Department Signature Date

3 Introduction & Scope 7

8 List of Execution Personnel 8

10 Acceptance Criteria Summary 9

Support - Training Verification 53

Ref. Document No. Document Title

1.1 Verification with as built P&ID

Date Version Revised By Reason for Revision

3 Introduction & Scope

System Equipment Description Qty Design Parameters

Control Panel w/ PLC

8 List of Execution Personnel

Ref. Name Organization Designation Signature Date

Deviation Deviation Description Date Resolved Initial and

Deviation Deviation Description Date Resolved Initial and

10 Acceptance Criteria Summary

10.1 Pre-commissioning checklist

A/C. Acceptance Criteria A/C Met? Test Sheet Reference Initial

The pre-commissioning checklist of hot water Annexure 1_Pre-

A/C. Acceptance Criteria A/C Met? Test Sheet Reference Initial

Operation and maintenance documentation is O&M shall be provided part of

Devices have been calibrated in compliance 0066_Documentation -

The installation has been verified as correct 0011_ Installation Verification

System specified installation checks have 0011_ Installation Verification

Hardware installation meets the design 0058_ Control Verification –

Alarms and interlocks operate to design 0055_Alarm and Interlock

The system performance meets design HWG/001_1_Commissioning

Test Instrumentation used during completion 0006_ Support – Test

The signature register has been completed 0009_ Support – Signature

Test Sheet Title Test Sheet Ref.

Pre-Commissioning Checklist Annexure 1

Documentation - Pre-Requisite Documentation Review 0013

Installation Verification – Hot Water Generation Skid 0011

Documentation - Calibration Verification Record (General) 0066

Control Verification - Password Access (General) 0057

Alarm and Interlock Verification – General 0055

Commissioning Report HWG/001_1

Pump Commissioning Report Annexure 2

Performance Verification – Flow, Pressure & Temperature Verification Test HWG/001_2

Support – Signature Record 0009

Title: Documentation – Pre-Requisite Documentation Review Reference: 0013

Specification for Hot Water Generation IN5010049-42-SP-0003_D_01

HMI-GXU5512 catalogue HMI-GXU5512

Title: Documentation – Pre-Requisite Documentation Review Reference: 0013

Title: Installation Verification – Hot Water Generation Skid Reference: 0011

Title: Installation Verification – Hot Water Generation Skid Reference: 0011

Title: Installation Verification – Hot Water Generation Skid Reference: 0011

Title: Installation Verification – Hot Water Generation Skid Reference: 0011

Title: Installation Verification – Hot Water Generation Skid Reference: 0011

Make: Expert Engineering Enterprises

Title: Installation Verification – Hot Water Generation Skid Reference: 0011

Title: Installation Verification – Hot Water Generation Skid Reference: 0011

Make: L&T Valves Ltd.

Make: Darling Muesco

Title: Installation Verification – Hot Water Generation Skid Reference: 0011

Make: Mahavas Precision Controls