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Pilot scale test specification
Autoclave System Test Specification:
Pre-Starting
Please read these instructions thoroughly. This will make sure you obtain full safe use, Keep this instruction manual in a handy place for future reference.
Filling the tank
- Make sure all valves are closed
- Make sure the power is turned off
- Connect the water valve to autoclave
- Open the water to fill the tank (amount of water should be between 60-70%)
- Close the valve for water filling
Safety precaution
The hot water (121 °c) could suffer of second-degree burns
Autoclave operation method
1-Ensure all sanitary connections
2-Fill the autoclave tank with water
3-Plug the control system to electricity
4-check the control system if it works properly (Check if the valves works by turning them ON and OFF)
5-Operate the heater
6- Wait till the water transforms to steam (T= 121°C / P= 20000 Pa), operate the autoclave valve system to open
7-After finishing, Operate the pipe to open (to decrease the pressure)
System testcases
001: test the resistor of the autoclave
Step |
Step Description |
Expected Result |
Precondition |
System is off |
|
Switch on the system |
Turn on the heater |
The water degree starts to going up to reach 121°c |
Switch off the system. |
Turn off the heater |
The water will remain warm and could last for 5-6h |
Postcondition |
System is off |
|
002: AUTOCLAVE SYSTEME TEST OF PENICILLIN PRODUCTION
Step |
Step Description |
Expected Result |
Precondition |
System is OFF |
|
open/close the valves |
open all valves from the control panel and reclosed them after few minutes |
Release the air from the system |
Switch on the heater |
Turn on the heater from the control panel |
THE SYSTEM IS heating the water till reach 121°C |
Sterilization of the fermenter |
Open the autoclave valve (autolave--->Autoclave valve) |
The steam is filling the fermenter |
Sterilization of the whole system |
Open the fermenter valve to sterilize last 2 tanks (autolave--->fermenter--->fermenter valve) |
Pressure should reach 2 atm (20000 Pa) and temperature 121 °C |
Open the manual discharge valve |
Open the discharge valve manually |
Pressure should decrease and the steam vent off the system |
CLose the valves |
close ALL the valves from the control panel and the discharge valve manually |
ALL the valves are closed |
switching OFF the system |
switch off the system |
the system is OFF |
Postcondition |
system is OFF |
|
Aspirin Production System Test Specification:
Pre-Starting
Please read these instructions thoroughly. This will make sure you obtain full safe use, Keep this instruction manual in a handy place for future reference.
Prepare the reactor
- Make sure all valves are closed
- Make sure the power is turned off
- Connect the reactif valve to the reactor
- Put the amount needed of the reactifs in the reactor (amount of reactifs: 1013.5g of salicylic acid, 2.5L acetic anhydride and 125ml concentrated H2SO4)
- Closed the valve for reactifs filling.
Safety precaution
-The hot water (80 °c) could suffer some burns (tank number 2)
-Concentrated Sulfuric acid causes severe skin burns and eye damage. (Wear protective gloves/protective clothing/eye protection/face protection).
Aspirin Production operation method
1-Ensure all sanitary connections
2-Put the reactifs in the reactor (salicylic acid, acetic anhydride and H2SO4)
3-Plug the control system
4-check the control system if it's works properly
5-Operate the mixer to mix the reactifs in the reactor
6-Operate to add warm water to the mixture
7-Open the valves to reach the filtration system
8-Operate to open the vacuum pump in the filtration system
9-Operate the valves to refiltration the aspirin
7-After finishing, Operate the pipe to close.
System testcases
003: AUTOCLAVE SYSTEME TEST OF ASPIRIN PRODUCTION
Step |
Step Description |
Expected Result |
Precondition |
System is off |
|
open/close the valves |
open all valves from the control panel and reclosed them after few minutes |
The air is Released from the system |
Switch ON the heater |
Turn on the heater from the control panel |
THE SYSTEM IS heating the water till reach 121°C |
Sterilization of the reactor (tank 1) |
Open the autoclave valve V0/1 (autolave--->Autoclave valve V0/1) |
The steam is filling the reactor (tank 1) P= 2 atm (20 000 Pa)/T= 121 °C |
Sterilization of the cooler (tank 2) |
Open the reactor valve (tank 1) to sterilize the cooler (autolave--->Reactor--->Reactor valve V1/2) |
The steam is filling the reactor (tank 1) and the cooler (tank 2) P= 2 atm (20 000 Pa)/T= 121 °C |
Sterilization of the crystallizer (tank 4) |
Open the cooler valve (tank 2) to sterilize the crystallizer (autolave--->cooler---> cooler valve V2/4) |
The steam is filling the reactor (tank 1), the cooler (tank 2) and the crystallizer (tank 4)
P= 2 atm (20 000 Pa)/T= 121 °C |
Sterilization of the vacuum filter (tank 5) |
Open the crystallizer valve (tank 4) to sterilize the vacuum filter (autolave--->crystallizer--->crystallizer valve V4/5) |
The steam is filling the reactor (tank 1), the cooler (tank 2), the crystallizer (tank 4) and the vacuum filter (tank 5) P= 2 atm (20 000 Pa)/T= 121 °C |
Sterilization of the waste tank (tank 6) |
Open the vacuum filter valve (tank 5) to sterilize the waste tank (autolave--->vacuum filter--->vacuum filter valve V5/6) |
The steam is filling the reactor (tank 1), the cooler (tank 2), the crystallizer (tank 4), the vacuum filter (tank 5) and the waste tank (tank 6)
P= 2 atm (20 000 Pa)/T= 121 °C |
Open the manual discharge valve |
Open the discharge valve manually |
Pressure should decrease and the steam vent off the system |
Switch OFF the heater |
Turn OFF the heater from the control panel | the heater is OFF |
CLose ALL the valves |
close ALL the valves from the control panel and the discharge valve manually |
ALL the valves are closed |
switching OFF the system |
switch off the system |
the system is OFF |
Postcondition |
system is OFF |
|
004: ASPIRIN PRIDOUCTION SYSTEME TEST
Step |
Step Description |
Expected Result |
Precondition |
System is OFF |
|
TURNING ON the system |
Turn ON the control panel
|
The system is ON |
Switch on the mixer (tank 1) |
Turn on the mixer from the control panel (Reactor--->Mixer ON) |
Mixing the reagents to obtain the mixture in the reactor (tank 1) |
Open the valve V1/2 (tank 1) |
Open the valve V1/2 to transfer the mixture from tank 1 (reactor) to tank 2 (cooler) (Reactor---->Reactor valve V1/2) |
The mixture is transferred to cooler (tank 2) |
Open the valve V3/2 (tank 3) |
Open the valve V3/2 to add 5L warm water from WARM WATER TANK (tank 3) to the cooler (tank 2) (WARM WATER TANK---->WARM WATER TANK valve V3/2) |
The warm water is in the cooler (tank 2) with the mixture |
Open the valve V2/4 (tank 2) |
Open the valve V2/4 to transfer the mixture from cooler (tank 2) to crystallizer (tank 4) (cooler---->cooler valve V2/4) |
The reagents are transferred to the crystallizer (tank 4) and formation of crystals |
Switch on the vacuum pump |
Turn on the vacuum pump from the control panel (crystallizer---->crystallizer pump ON) |
The air is vacuumed in tank 6 |
Open the valve V4/5 and V5/6 |
Open the valve V4/5 and V5/6: 1-the vacuum filtration begin 2-Aspirin crystals are now in the vacuum filter (tank 5) (1-crystallizer---->crystallizer valve V4/5) (2-vacuum filter---->vacuum filter valve V5/6) |
The filtrate transferred to the waste tank (tank 6) |
Open the valve V3/5 |
Open the valve V3/5 to add 30L warm water from WARM WATER TANK (tank 3) to vacuum filter (tank 5) (WARM WATER TANK---->WARM WATER Valve V3/5) |
Crystals re-dissolved with 30L warm water after 20min in the vacuum filter (tank 5) |
Open the valve V5/4 |
Open the valve V5/4 The solution is pumped from tank 5 to tank 4 for the second crystallization (vacuum filter---->vacuum filter Valve V5/4) |
Solution transferred to the crystallizer (tank 4) and start the crystallization |
Switch on the vacuum pump for the second filtration |
Turn on the vacuum pump from the control panel (vacuum filter---->vacuum pump ON) |
The air is partial vacuumed in tank 6 |
Open the valve V4/5 and V5/6 |
Open the valve V4/5 and V5/6: 1-the vacuum filtration begin 2-Aspirin crystals are now in the vacuum filter (tank 5) (1-crystallizer---->crystallizer valve V4/5) (2-vacuum filter---->vacuum filter valve V5/6)
|
The filtrate transferred to the waste tank (tank 6) |
switching OFF the system |
switch OFF the system |
the system is OFF |
Postcondition |
system is OFF |
|