Training reports GIT at IET

7/30/2019 Training reports GIT at IET

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- NATIONAL DIPLOMA IN ENGINEERING SCIENCES -

1 GENERAL INDUSTRIAL TRAINING REPORT

PREFACE

NATIONAL DIPLOMA IN ENGINEERING SCIENCES is the one of the most reputed

Engineering diploma in the Sri Lanka and the Worldwide. It provides the Middle Level

Engineering Managerial every year in Civil, Electrical and Mechanical fields. The 2 Years of

Industrial Training of the program provides the higher knowledge and practice in the relevant

fields for each NDES diplomats.

As engineering student, practical knowledge is very important as well as

theoretical knowledge to become a skilled engineer in future and also it is very important fact that

industrial experience. This report contains the important things of the work done and my

experience.

This Training Report is based on the General industrial training program

Mechanical engineering (General).


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ACKNOWLEDGMENT

With the completion of my report, I would like to pay my sincere gratitude to NAITA, IET,

Elastomeric Technologies (PVT) Ltd. and State Pharmaceuticals Manufacturing Corporation

(SPMC).

I would be grateful to Mr. J. A. F. Senewirathne Head of Mechanical

Engineering (training) Department, for the valuable and vital guidance given and for the precious

time spent on training period.

My special thank would go to,

Mr. Rukman Chaminda, Engineering manager of Elastomeric Technologies (PVT) Ltd and

Mr. M.D.A.R. Gunarathne, Engineering manager of State Pharmaceuticals manufacturing

corporation , and Mr. D.A.J.S. Dharmapriya ,Operation Manager ,Mr.H.A.N. Hettiarachchi

,Deputy Operation Manager,foreman and all workers and staff of garage section of Ceylon

petroleum storage terminals ltd, For the kind guidance.

Finally, I must mention all the workers who supported me in the limited training period .

Thank you,

T.A.D.J.Chameera

MG/09/7728


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CONTENTS

1. ELASTOMERIC TECHNOLOGIES PVT (LTD)

1.1 Introduction .5

1.11 Functions of the organization ... 5

1.12 The 5S concept ..... 7

1.13 Air Conditioning Cycle.15

1.20 Refrigerant Compressor And Condenser16

1.21 Compressor....16

1.30 Condenser.21

1.31 Condenser Types..21

1.40 Cooling Towers.25

1.50 AIRHANDLING

UNITS..................................................................................................31

1.60 Fan Coil Unit32

1.70 Chilled Water System34

1.80 Ducting....................................................................................................................37

2 SWEDISH TRADING COMPANY (Private) LIMITED

2.1 Air Compressors.40

2.11 Types of air compressors40

2.12 Piston compressors..42

2.13 Tooth Compressor.43

2.14 Scroll compressor.44

2.15 Vane Compressor.45

2.16 Screw Compressors...45

2.17 Oil-Free Screw Compressors..46


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1

ELASTOMERIC TECHNOLOGIES PVT (LTD)


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1.1 INTRODUCTION

Elastomeric is a part of HEXPOL, which manufacturing in North America, Europe and

Asia pacific. HEXPOL is a multinational company. It is a globally leading supplier of polymeric

wheels and other products for the transport and material handling industry. Elastomeric was

founded in 1992. It was acquired by Hexagon in 1998. Mother company is situated in Sweden.

Factory spread over 5 acres land in Sri Lanka. More than 500 workers are working in the factory

at Bokundara. Other factory is located in Horana.

1.1.1 Functions of the organization

Gasket for plate heat exchangers (PHEs) and black tire compound mixing is done at the

Bokundara factory. Solid tire and caster wheels are manufactured in Horana. Following process

are carried out in Bokundara premises. .

Mould designing (tool shop)

Gaskets manufacturing (Compression molding)

Extruding

Compound mixing

Post curing

Elastomeric has its own mould shop. So they can make compression moulds. Their tooling

facility facilitate them to response their customer inquiries very quickly. R&D department can

achieve customer requirement as soon as possible. Production department also work together

with R&D to provide better service to their customers. Production department work hard and

use their full strength to supply good quality products on time to their customers. Elastomeric

export their total output to various countries in Western Europe, USA, Japan and Australia.

Sales and marketing of Elastomeric products in Europe and USA are handled through Stellana

AB of Sweden which is subsidiary company of HEXPOL. Sales and marketing in Asia is

handled by Office in Sri Lanka.


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Vision

It is our vision to be universally regarded as an efficient customer focused quality supplier, which globally

brings value to customers through innovation.

Mission

Our mission as a wheel specialist is to develop, manufacture and market high quality wheels and adjacent polymer

products for transport and material handling.

The plant at the Bokundara is the only gasket manufacturing plant in Sri Lanka .It was my

training place. It produced More than 7000 quality approved gaskets are produced in plant per

week. Nearly 60 compression mould presses, 3 rubber extruders and 15 curing ovens are operated

in gasket production plant. Workers work according to shift basis in both gasket and mixing

department. In gasket two shift systems available. One shift system operates according to 12 hours

basis and the other 8 hours basis. Normally plant runs 6 days per week but workers in gasket

department can work Sunday if they like. However plant was shut down during Sunday night

shift.

The company is running successfully and contributes to Mother Company as well employees. The

success of the company lies on the hand of the employees and the practices involved within the

company itself.

Elastomeric has a strong management who steering the company towards success. All department

heads work together to achieve the company goals and enhance the productivity of the company.

They are very familiar with the process and workers under them. They work very closely with

supervisors and workers to solve the problems involve in production. They learn from experience

and practiced in present.

Engineering manager work hard to resolve the problem entitled in machineries during production.

Research and development department is the heart of the company. They work hard to develop the

quality of products and satisfy the customer. They help to run smooth production.

Mould designing department also help to maintain the quality of the products and achieve

customer requirement


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1.1.2 THE 5S CONCEPT

This is a factory, which follows 5S concept. When considering about the 5S it is the name

of a workplace organization method that uses a list of five Japanese words: seiri,seiton,seiso,

seiketsu, and shitsuke. Transliterated or translated into English, they all start with the letter "S".

The list describes how to organize a work space for efficiency and effectiveness by identifyingand storing the items used, maintaining the area and items, and sustaining the new order. The

decision-making process usually comes from a dialogue about standardization, which builds

understanding among employees of how they should do the work.

When considering the English meaning of main parts of the 5S concept, they are,

Sorting

Eliminate all unnecessary tools, parts, and instructions. Go through all tools, materials, and

so forth in the plant and work area. Keep only essential items and eliminate what is not required,

prioritizing things per requirements and keeping them in easily-accessible places. Everything else

is stored or discarded.

Straightening or Setting in Order

Arranging tools, parts, and instructions in such a way that the most frequently used items

are the easiest and quickest to locate. The purpose of this step is to eliminate time wasted in

obtaining the necessary items for an operation.

Sweeping or Shine

Clean the workspace and all equipment, and keep it clean, tidy and organized. At the end

of each shift, clean the work area and be sure everything is restored to its place. This makes it easy

to know what goes where and ensures that everything is where it belongs.

Standardizing

All work stations for a particular job should be identical. All employees doing the same

job should be able to work in any station with the same tools that are in the same location in every

station. Everyone should know exactly what his or her responsibilities are for adhering to the first

3 eases. Synonym : Systemize.

Sustaining the Practice

Maintain and review standards. Once the previous 4 eases have been established, they

become the new way to operate. Maintain focus on this new way and do not allow a gradual

decline back to the old ways. While thinking about the new way, also be thinking about yet betterways. When an issue arises such as a suggested improvement, a new way of working, a new tool

or a new output requirement, review the first 4 eases and make changes as appropriate. It should

be made as a habit and be continually improved.
http://en.wikipedia.org/wiki/Japanese_languagehttp://en.wikipedia.org/wiki/Transliterationhttp://en.wikipedia.org/wiki/English_languagehttp://en.wikipedia.org/wiki/English_languagehttp://en.wikipedia.org/wiki/Transliterationhttp://en.wikipedia.org/wiki/Japanese_language


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1.1.3 ABOUT GASKETS

These gaskets are use in plate heat exchangers. A plate heat exchanger is a type of heat

exchanger that uses metal plates to transfer heat between two fluids. This has a major advantage

over a conventional heat exchanger in that the fluids are exposed to a much larger surface areabecause the fluids spread out over the plates. This facilitates the transfer of heat, and greatly

increases the speed of the temperature change. Plate heat exchangers are now common and very

small brazed versions are used in the hot-water sections of millions of combination boilers. The

high heat transfer efficiency for such a small physical size has increased the domestic hot water

(DHW) flow rate of combination boilers. The small plate heat exchanger has made a great impact

in domestic heating and hot-water. Larger commercial versions use gaskets between the plates,

smaller version tend to be brazed.


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Many types of gaskets are manufacturing in elastomeric. Types of gaskets are M15B,

CLIPPON, M10B, M20M, MX25B, J185, AK20 etc. They are named according to design.

Gaskets are available in various lengths. They varied from 0.5m to 3.0m. They manufacture

gaskets for Alfa Lavel, APV, GEA, Hisaka, API schmidt, Sondex, Swep, Trante etc. Acrylonitrile

Butadiene Rubber (NBR), Ethylene propylene Diene Monomer (EPDM), Butyl rubber (IIR),

Hydrogenated Nitrile (HNBR) and Fluorocarbon (FKM) are use for gasket manufacturing. Most

of compounds are NBR and EPDM based. Every compound has number.

EPDM 70804, 70806, 70807, 70812, 70814, 70816, 70817, 70824, 70826, 70829, 70840, NBR

63614, 63746 , 63811 , 63812, 63829 , 63830 , 63805 , 63815

Not only the material, but also the gasket types are varied according to the design & size of

gaskets.

The EPDM gaskets used in plate heat exchangers have Weather Resistant property & NBR

gaskets have Oil Resistant property. Also NBR have heat resistant in different Temperatures

(80C-800C). The gaskets of 63830 material of NBR can be used food applications such asYogurt, Cheese, Souse, Bear and MilkTemperature 90C). Also the gaskets of 70840 & 70817

materials of EPDM are used to food applications.


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PROCESS FLOW CHART

Basically, the factory can divide into 6 major pats. They are,

1. Mixer and Mill area.

2. Extruder Area.

3. Press Area

4. Oven Area.

5. Tool section

6. Boiler area.

7. Nitrogen gas generator.

COMPOUND

RECIEVED

INSPECTION EXTRUDING

EXTRUDER

MOULDING (PRESS)

CUT TO SPECIFIED

LENGTH

INSPECTION

INPROCESS

INSPECTION

POST CURING

BUNDELING

SAMPLE

INSPECTION

LABELLINGDISPATCH PACKAGING &

FINAL INSPECTION


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1.2.0 MIXER AND MILL AREA

This is the area which belonging to the mixing department. The main objective of

this department is convert raw rubber into a form, which is suitable for the production. In here

they produced rubber batches which required to make solid tires.

Raw rubber alone is not suitable for the production of useful articles. It is due to following

reasons:

1. It is tough and cannot be shaped easily in the form of an article

2. Low temperature softening

3. Its strength is weak

4. Molecular degradation undergoes easily.

5. Due to high cost of rubber.

So to make useful products at reasonable cost, it is necessary to compound raw rubbers

with other chemical ingredients. These ingredients are classified according to their function.

Compounding Ingredients Function in rubber

Chemical plasticizer To increase level of plasticity

Filler To increase strength, Hardness and reduce cost

Softeners To aid filler incorporation into rubber

Antidegradant To increase service life of rubber product

Vulcanizing system To form crosslinks among rubber molecules.

1.2.1 BATCH MIXER

The batch mixer is a machine, which is used to mix ingredients according to a

specified formula. And they used two roll mill for mix the batch further. After that the batch sends

through Batch Off machine to clean and pack the batch properly.

When considering the Batch mixers, there are two basic types.

1. Banbury Type.

2. Intermix Type.

In Bokundara factory we can found a Intermix type mixer of 210 liter capacity .


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The mixer was made in India. It is PLC controlled. The mixing procedure changes from

compound to compound. Mixing procedure was entered to program for each compound type.

Carbon black, china clay, whitening and oil feed automatically. Rubber and other chemicals are

feed manually through feed door. The rotors of mixer run by DC motor. The motor speed can

change. Power rating of the mixer is 1000kw / 1000 r.p.m. The maximum speed of rotor is

56rpm. If motor exceed this value it is stopped. There are 2 pump oil lubricating system for the

motors. It is help to cool motor components.

Usually mixing procedure controlled by time or temperature. End of the mixing cycle

discharge door opens automatically and batch discharge on two roll mill. But compound is not

always mixed properly at the end of mixing. So mixer operator observes the behavior of ram and

decides the mixed level. By the experience mixer operator knows whether batch is mixed or not.

Internal Mixer


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1.2.2 TWO ROLL MILL

A two roll mill is use to mix the batch further. The output of the batch mixer is

directly fed into the two-roll mill.

Mill was placed under the mixer. So discharging batch from mixer directly put on

mill nip. Mill also used for adding sulphur to gasket compounds. This mill is single geared mill. It

is powered by 160kw motor and simple band break system is used to break it. In this mill the back

roll is driven from the gearbox or backshaft, and the front roll from the back roll through roll end

gears. Front roll can move forward and back. Clearance between two rolls is called nip. It can

adjust by moving front roll. Nip can adjust from 1-14mm. This adjustment is carried out by

electric motor. Speed of the back roll is higher than front roll. Front roll to back roll speed ratio is

1.0:1.2. Two roll mill is cooled by circulating chilled water. Rotary joint is used to supply chilledwater into the mill rolls. Guides are fitted the roll ends to prevent rubber being contaminated with

grease etc. Cutting knives are provided under to rolls in front roll side to cut rubber. Width

between knives is same to width of conveyer belt of batch off. Metal tray is provided under the

two rolls. So ingredients which dropped on tray can collect easily and remix.

1.2.3 BATCH OFF

This is a PLC controlled machine which is used to cool the sheeted compound. Batch off

consist with tank consisting antitack solution and cooling fans. Sheeted batch from two roll mill is

placed on conveyer belt of the batch off and it was started. Rubber sheet was went trough antitack

solution and entered to fan area. In this area rubber sheet cooled and dried out. Rubber batch was

taken out from end of batch off. Rubber batch was packed on pallet.


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These units consisted with various types of sensors and Transducers. They are,

1. Load Cells

2. Proximity sensors3. Temperature sensors (RTD)

4. Taco generators

5. Photo electric sensors.

1.LOAD CELL

Load cells are sensors which are used to measure the level or pressure by converting the

force (torque or mass) into electrical signals and then these signals are displayed by the display

unit to show the level or pressure.

Load cells are also known as load transducers.

There are various types of load cells, they are Strain gauge load cells, Tension load cells,

Pneumatic load cells, Hydraulic load cells, Shear Load Cells, Compression Load Cells, Bending

Load Cells, Ring Torsion Load Cells, Pancake Load Cells, Single Point Load Cells

2. PROXIMITY SENSORS

A proximity sensor can detect metal targets approaching the sensor, without physical

contact with the target. Proximity sensors are roughly classified into the following three types

according to the operating principle: the high-frequency oscillation type using electromagnetic

induction, the magnetic type using a magnet, and the capacitance type using the change of

capacitance.


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3.RESISTANCE TEMPERATURE DETECTOR(RTD)

An RTD is a device which contains an electrical resistance source (referred to as a

sensing element or bulb) which changes resistance value depending on its temperature. This

change of resistance with temperature can be measured and used to determined the temperature of

a process or of a material.

RTD sensing elements come in two basic styles, wire wound and film

4. TACHO GENERATOR

An electromechanical generator is a device capable of producing electrical power from

mechanical energy, usually the turning of a shaft. When not connected to a load resistance,

generators will generate voltage roughly proportional to shaft speed. With precise construction

and design, generators can be built to produce very precise voltages for certain ranges of shaft

speeds, thus making them well-suited as measurement devices for shaft speed in mechanical

equipment. A generator specially designed and constructed for this use is called a tachometeror

tachogenerator.

5. PHOTO ELECTRIC SENSOR

A photoelectric sensor is a device used to detect the distance, absence, or presence of an

object by using a light transmitter, often infrared, and a photoelectric receiver. There are three

different functional types: opposed (through beam), retro-reflective, and proximity-sensing

(diffused).
http://en.wikipedia.org/wiki/Infraredhttp://en.wikipedia.org/wiki/Photoelectric_effecthttp://en.wikipedia.org/wiki/Photoelectric_effecthttp://en.wikipedia.org/wiki/Infrared


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1.3 EXTRUDER AREA

This is a machine which used to make rubber blanks. Elastomeric has 3 extruders.

All the extruders are cold feed pin extruders. Final blank is long cylindrical rubber piece.

Dimension of blank are diameter, length and weight. Blank dimension varies according to gasket

type. Blank dimension can controlled by changing die diameter, Extruder speed, conveyor speed,

cooling temperature, traveling time and traveling speed. These details are available for operator as

chart.

This machine consisted with,

1. DC motor

Output : 75kwSpeed : Max 1150 rpm

Power Source : 3 Phase, 415V / 50Hz

2. Gear Box

Transmission : Double reduction type

Reducing ratio : 1 / 19.2

Input Speed : Max 1150 rpm

Lubricating method : By trochoid pump

Coupling method : By gear Coupling

3. Water heating system

For heat the extruding compound.

4. Automatic Cutting System

To cut the blanks according to the given length.

5. An air chiller unit.

To produce chilled water for cool the blank before cutting into the given length. This helps

to reduce shrinkage error.

When considering about this machine, we can set the speed of the DC motor speed by

using the knob of the control panel. The DC drive is used to control the speed of the motor with

the help of a Tachogenarator which was connected to the rare part of the motor shaft. In here

controlling speed means controlling the output by means of reducing the mixing time. So, they

have to be controlled in specified manner by the operator.


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The output of the extruder is rubber blanks. To cut those blank into a specified length a

automatic cutter is used. This cutter consisted with rotary potentiometer which is used to measure

distance of the blank travels operate the cutter in specified position.

1.3.1 POTENTIOMETERS

Figure shows three types of potentiometric devices for measuring displacement.

The potentiometer shown in Figure (a) measures translational displacements from 2 to 500 mm.

Rotational displacements ranging from 108 to more than 508 are detected as shown in Figure (b)

and (c). The resistance elements (composed of wire-wound, carbon-film, metal-film, conducting

plastic, or ceramic material) may be excited by either dc or ac voltages. These potentiometers

produce a linear output (within 0.01%of full scale) as a function

of displacement, provided that the potentiometer is not electrically loaded. The resolution of thesepotentiometers is a function of the construction. It is possible to achieve a continuous stepless

conversion of resistance for low resistance values up to 10 V by utilizing a straight piece of wire.

For greater variations in resistance, from several ohms to several megohms, the resistance wire is

wound on a mandrel or card. The variation in resistance is thereby not

continuous, but rather stepwise, because the wiper moves from one turn of wire to the next. The

fundamental limitation of the resolution is a function of the wire spacing, which may be as small

as 20 mm. The frictional and inertial components of these potentiometers should be low in order

to minimize dynamic distortion of the system.

A ROTARY POTENTIOMETER


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The cutter is operated by a motor and it should be break at given position to cut the blanks

to a specified length. So the motor should have a breaking system. An electromagnetic breaking

system is used here to achieve this.

1.3.2 ELECTRO MAGNETIC BREAKING SYSTEM

When the voltage is applied to the coil, the armature plate that is suppressed by the spring

is pulled to thrust the spring to make a gap between the armature and the brake to release the

braking force , when the voltage is removed the spring fore is helped to seat the armature plate

with break lining.


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1.4. PRESS AREA

There are several types of hydraulic presses are used to produce gaskets from rubber

blanks. Basically, the presses are classified according to their Tonnages. It means the maximum

clamping force it can apply in a given oil pressure. There are several types of presses are available

here for various types of gasket moulds.

Every press consisted with 2 or 3 help cylinders and 1, 2 or 3 main cylinder. The help

cylinders are helps to raised the platen into predetermined position and the main cinder(s) gives

the final clamping force.

For an example if we consider an 800 ton press,

It has, Main ram cylinder - 500mm dia. (2) , Help cylinder - 150mm dia. (2) and if it can

works at 210 kg/cm2 oil pressure. Then we can calculate the maximum clamping force of it.

Where,

P - Pressure

A - Area

= 1963.5 cm2

So the maximum clamping force

= 824670kg

Every press controlled with its own PLC unit. Control means, starting, stopping,

High-pressure start, low pressure cut - off, bumping time, curing time and safety limit switches.

Shihlin Electric - AX2 - 32MR PLC controller is used.

In an every press hydraulic system is basically consisted with, Relief valves, Directional

valves, Pilot operated valves, Flow control valves, Check valves and pressure reducing valve.


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1.4.1 PRESSURE RELIEF VALVE

A relief valve functions to bleed pressure off to return (by creating an open flow

path to return) when a prescribed pressure level is reached. Relief valves are simple devices

(similar to check valves) where a piston or poppet is held closed by a spring. The spring is set

such that the poppet will open, providing a flow path to return, when pressure reaches a prescribed

level. Every hydraulic systems requires at least one pressure relief valve to protect the system

against thermal expansion and excessive pressure transients. The relief valve setting provides

burst protection for all components in a system.


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But for those presses they used solenoid controlled relief valves. These valves are a

combination of a pilot operated relief valve and a solenoid operated directional valve. Piping

between the two is eliminated as the solenoid valve is directly mounted on the relief valve and

connected with the relief valve vent. Pump pressure may be unloaded remotely by an electrical

signal to the solenoid, or by connecting pilot relief valves to the solenoid valve ports.

According to the model of the valve, a vent restrictor is added between a relief valve and a

solenoid operated directional valve. If prevents shock to the main circuit by gradually lowering

the venting pressure in the shift from the set pressure to unloading.

Unloading pressure are the same as without a vent restrictor.

1.4.2 DIRECTIONAL VALVES

Directional valves are valves that direct flow in response to external commands.

Directional valves are usually servos (see servos) where the servo is positioned in response to

solenoids, torque motors or mechanical input. Directional valves do not provide flow or pressure

regulation and functional only to direct flow (much like a switch).

Directional valves are referenced by the number of positions the spool will take (2, 3 or 4

positions are typical) and the number of hydraulic ports in the valve (2 way, 3 way and 4 way are

typical). Examples are shown below.

Two Way, Two Position (2/2) Valve

The schematic of valve with a vent

restrictor


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In a two way, two position valve, the servo can be in one of two positions and the two

ways because there are 2 fluid ports in the valve (or, if you prefer, the valve housing). Although a

spool arrangement is shown, any type of check valve could be considered a two way, two position

valve.

Three Way, Two Position (3/2) Valve

In a three way, two position valve, there are three inlet/outlet ports in the valve and the

spool can be in one of two positions. A 3/2 valve would be used to allow fluid flow into or out of

actuator or motor.

Four Way, Two Position (4/2) Valve

In a four way, two position valves there are four inlet/outlet ports in the valve and the

spool can be located in one of two positions. For 4/2 valve fluid is always flowing through the

valve with system pressure supplied to one of the two outlet ports at all times. The other port

would then be ported to return. 4/2 valves would normally be used in hydraulic systems in

conjunction with an upstream shut valve (or 2/2 valve). In this case a 4/3 valve usually makes

more sense. However, 4/3 valves can be found in power control units (PCUs), where a shutoff

valve is installed in the PCU where a shut valve is not packaged with the 4/2 valve due to other

design considerations in the PCU.


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Four Way, Three Position (4/3) Valve

In a four way, three position valve, the spool is in one of three positions and there are 4inlet/outlet ports in the valve. In the midstroke position there is no flow through the valve. A good

application of a 4/3 valve is actuator control, where the actuator control goal is to extend, retract

or hold a position. 4/3 valves are used in servo valves, where the spool is controlled by a flapper

valve or a jet pipe valve.

The presses commonly used directional valves are Solenoid operated 4/2 way and 4 way 3

position manipulator with 3 position detent. In here manipulator means, either position operates a

cylinder port with the opposite port drained to tank, center position cylinders drain to tank andpressure port blocked.

solenoid operated 4 - way 2 position valve


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1.4.3 VANE PUMP

A rotary vane pump is a positive-displacement pump that consists of vanes

mounted to a rotorthat rotates inside of a cavity. In some cases these vanes can be variable

length and/or tensioned to maintain contact with the walls as the pump rotates.

The simplest vane pump is a circular rotor rotating inside of a larger circular

cavity. The centers of these two circles are offset, causing eccentricity. Vanes are allowed

to slide into and out of the rotor and seal on all edges, creating vane chambers that do the

pumping work. On the intake side of the pump, the vane chambers are increasing in

volume. These increasing volume vane chambers are filled with fluid forced in by the inlet

pressure. Inlet pressure is actually the pressure from the system being pumped, often just

the atmosphere. On the discharge side of the pump, the vane chambers are decreasing in

volume, forcing fluid out of the pump. The action of the vane drives out the same volume

of fluid with each rotation.
http://en.wikipedia.org/wiki/Pumphttp://en.wikipedia.org/wiki/Rotor_%28turbine%29http://en.wikipedia.org/wiki/Rotor_%28turbine%29http://en.wikipedia.org/wiki/Pump


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DOUBLE VANE PUMP

single pumps combined in tandem within a single housing and driven by a common shaft.

A Single suction port and two discharge ports are provided so that the output flow can be suppliedto separate circuits.

1.4.4 HYDRAULIC CYLINDER

A hydraulic cylinder is a mechanical device for transferring power by the use of high

pressure oil acting against the surface area of a piston within the cylinder.

A hydraulic cylinder provides linear force in one axis in either one or two directions (known as a

single or double acting cylinder respectively).

The cylinder is typically made up of 4 or 5 components:

- Tube

- Piston (optional)

- Rod

- Gland

- End cap


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In a typical hydraulic cylinder with a piston oil is fed in at either end via some type of

'port' and the piston is sealed to the tube by a double acting seal and also between the rod and the

gland by a single acting seal. In addition, you will usually find a wiper seal is used in the gland to

keep dirt out. This illustration is known as a double acting cylinder.

It is the pressure acting upon the piston surface which causes a the hydraulic cylinder toproduce a linear movement. Because the rod is fixed to the piston, it moves too. Application of

hydraulic pressure through the port to one side of the piston causes it to move in one direction,

and application of pressure through the port to the opposite side of the piston will cause it to move

in the opposite direction.

In a single acting cylinder, oil only acts on one side of the piston so it can only be

mechanically moved in one direction. An external force (gravity, or sometimes a spring or another

hydraulic cylinder) provides force in the opposite direction.

Single acting cylinders can also be of the "displacement" type where the oil pressure acts

directly on the end of the rod, and there is no piston. In this cylinder design the force is limited by

the surface area of the rod, whereas in a cylinder with a piston, the rod can be of any size and theforce can be calculated or controlled by the piston design.

Typically one end of the tube is fixed and on the end of the rod is attached the object to be

moved, although it is possible to fix the end of the rod, and attach the object being moved to the

end of the tube.

In a double acting cylinder the "closing" power is always less than the "opening" power

due to a reduced surface area of the piston for the oil to act upon. This reduced surface area is

exactly the surface area of the end of the rod.

An every press has its own steam supply system. When considring the main pats od that

system,

1. PRV (Prsssure Reducing Valve) - To control the tempreature

2. Inlet side header - A temporary storage of incoming steam

3. Outlet side header - A temporary storage of steam

4. Steam trps - To separate water from steam

STEAM FROM

HEADERPRV

HEADER

PLATEN

HEDER

STEAM TRAP

TO HOTWELL


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1.4.7 PRESSURE REDUCING VALVE

Pilot operated pressure regulator works by balancing the downstream pressure against a

control spring. This modulates a small valve head over a seat (the pilot). The flow through this

seat is directed, in turn, to the main valve diaphragm, where it modulates the main valve. In order

to achieve the most stable operating condition, an external pressure sensing line must be used.

This allows downstream pressure to feed back to the underside of the pilot diaphragm, balancing

the spring force, causing the pilot valve to throttle. This settles the

pilot valve, allowing a constant flow across the main diaphragm. This enures that the main valve

is also settled to give a stable downstream pressure. When downstream pressure rises, the pilot

valve closes, and pressure is released from the main valve diaphragm through the control orifice,

to close the main valve. Any variations in load or pressure will immediately be sensed on the pilotdiaphragm, which will act to adjust the position of the main valve, ensuring a constant

downstream pressure.

1.4.8 STEAM TRAPS

A steam trap is an automatic valve that allows condensate, air and other non-condensable

gases to be discharged from the steam system while holding or trapping the steam in the system.

When considering about they are basically 4 types,

1. THERMOSTATIC STEAM TRAPSThe bellows type thermostatic trap uses a fluid-filled thermal element (bellows) that

operates under the principle of thermal expansion and contraction. The fluid vaporizes and

expands as the temperature increases, causing the bellows to close the valve. As the temperature

decreases, the fluid condenses and contracts, causing the bellows to open the valve. These traps

provide excellent air handling capability and are used for drip, tracing and process applications.

The main advantage of the thermal element is that on start-up loads, the trap is in the open

position, allowing air and condensate to be rapidly removed from the system.


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2. BI - METALLIC STEAM TRAPS

The bi-metallic steam traps operate under the principle of thermal expansion of metals.

Two dissimilar metals are joined into a series of discs and upon heating will deflect to provide

movement to close off the valve. These traps are primarily used in steam tracing because of their

ability to adjust condensate discharge temperature which may be desirable on certain tracingapplications.

When cold condensate and air are present, the bimetallic trap remains open as the flow of air and

condensate discharges from the system. When steam arrives to the trap, the discs deflect and

pushes the plug onto the seat. The temperature at which the valve closes can be adjusted by

turning a set screw located on the top of the valve.

3. FLOAT AND THERMOSTATIC TRAPS

The float & thermostatic trap uses a float connected by a linkage to the valve plug to

discharge condensate from the system. In addition, F&T traps contain a thermostatic air vent toallow the discharge of air from the system. For this reason, these traps have excellent air removal

capability, which is advantageous during system start-up when large amounts of air are present in

the system. Float & thermostatic steam traps are generally the primary selection for drainage of

process heat transfer equipment.

4. INVERTED BUCKET TRAP

The inverted bucket trap uses an inverted bucket as a float device connected by a linkage

to the valve plug. The varying densities between condensate and steam are used to create a

buoyancy force on the bucket to open and close the valve. These traps are primarily used in drip

applications on stream mains and steam supply lines. They are generally not used in process

applications due to their poor air handling capability. Bucket traps are extremely rugged and

resistant to water hammer and also resistant to any dirt and scale that may be present in the

system.

5. THERMODYNAMIC STEAM TRAP

Thermodynamic steam traps operate in a cyclic on/off process using the thermodynamic

properties of flash steam as it flows through the trap. Thermodynamic traps use only one moving

part, the valve disc, which allows condensate to escape when present and closes tightly upon the

arrival of steam. These traps have an inherently rugged design and are commonly used as drip

traps on steam mains and supply lines. Their solid construction and single moving part make them

resistant to waterhammer and are freezeproof when installed vertically. Thermodynamic traps will

only discharge small amounts of air and therefore are typically not used in process applications.

These traps are used in press steam condensation outlets.


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1.5.0 OVEN AREA

Ovens are used to post currying of gaskets. Press output is tested and send to the

ovens and curried in specified temperature for improve hardness of gaskets. There are 16 Ovens in

the factory. According to the material some gaskets are curried by using normal air, some arecurried using Nitrogen and some are curried by using a mix of both.

When considering the technical details of an oven,

Temperature range : 25 - 200 OC (Not less than ambient)

Power : 80kw

Electrical supply : 400V / 3 phase

Heating : 2.8Wcm-2

Temperature control : Heat control with electronic temperature regulators. The regulators

control the contactors, which control the heating in their turn.

Air circulation : Air is sucked out of the Oven cavity, it is forced across the elements

and blown in at the side of the oven. The transitions for the fan

spindles are gas tight and a box where Nitrogen can be introduced ismounted beside the transitions.

Nitrogen Supply : 15 mm diameter copper tubes are used.

Gas is released rare part of the oven

When the oven is filled two pneumatically operated cylinders on the

roof top of the oven are opened in order to evacuate the air in the oven chamber.

(Nitrogen flow rate is 8 liters per second)

In here the J - type thermo couples are used to take tempreature from ovens and PID

controller with SCR unit is used to regulate the temperature. An every Oven consisted with its

own PLC unit.


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1.5.1 THERMOCOUPLE

A thermocouple circuit is formed when two dissimilar metals are joined at both ends and

there is a difference in temperature between the two ends. This difference in temperature

creates a small current and is called the Seebeck effect.

When there is a difference in temperature between the two ends of this circuit, a small

voltage is formed within the circuit. This voltage or EMF (electro motive force) is usually

measured in the 1/1000th of a volt (millivolt).

There are several different recognized thermocouple types available. Each type has

different useful temperature ranges as well as different recommended applications.

ASTM, which is recognized in the United States as the authority for temperature measurement,

has established guidelines for the different thermocouple types. These

guidelines cover composition, color codes, and manufacturing specifications.

J - type thermocouple

Type J thermocouples have an iron positive leg and a constantan negative leg.Type J thermocouples have a useful temperature range of 32 to 1400F (0 to 750C) and

can be used in vacuum, oxidizing, reducing and inert atmospheres. Due to the oxidation

(rusting) problems associated with the iron leg, care must be used when choosing this

type for use in oxidizing environments above 1000F.

The color code for type J is white for positive and red for negative.

Some other types of Thermocouples are , E- type, R - type, N - type, B - type, K- type , S-

type, B - type and C - type.

1.5.2 SCR (Power Regulator)

A silicon-controlled rectifier (or semiconductor-controlled rectifier) is a four-layersolid

state current controlling device. The name "silicon controlled rectifier" or SCR is General

Electric's trade name for a type ofthyristor. This device is generally used in switching

applications. In the normal "off" state, the device restricts current to the leakage current. When the

gate-to-cathode voltage exceeds a certain threshold, the device turns "on" and conducts current.
http://en.wikipedia.org/wiki/Solid_state_%28electronics%29http://en.wikipedia.org/wiki/Solid_state_%28electronics%29http://en.wikipedia.org/wiki/Electric_currenthttp://en.wikipedia.org/wiki/General_Electrichttp://en.wikipedia.org/wiki/General_Electrichttp://en.wikipedia.org/wiki/Thyristorhttp://en.wikipedia.org/wiki/Thyristorhttp://en.wikipedia.org/wiki/General_Electrichttp://en.wikipedia.org/wiki/General_Electrichttp://en.wikipedia.org/wiki/Electric_currenthttp://en.wikipedia.org/wiki/Solid_state_%28electronics%29http://en.wikipedia.org/wiki/Solid_state_%28electronics%29


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1.5.3 NITROGEN GAS GENERATOR

According to the product, gaskets are post curried using nitrogen, normal air or mix

of both. So Nitrogen is need for oven area. Therefore two nitrogen plants are established to fulfill

the Nitrogen need.

Nitrogen plant basic specifications

Electrical connection : 400V / 50Hz / 100A

Working Temperature : +5oC - 40oC

Max supply pressure : 10 bar

Delivery pressure (N2) : 8 bar

Capacity : 55 m3/ h

It is operate via the pressure swing adsorption (PSA) principle to produce a continuous

stream of nitrogen gas from compressed air. Pairs of extruded aluminum columns are filled with

carbon molecular sieve (CMS). Pre-treated compressed air enters the bottom of the online

column and flows up through the CMS. Oxygen and other trace gases are preferentially adsorbed

by the CMS, allowing nitrogen to pass through. After a pre-set time the on-line column

automatically switches to regenerative mode, venting contaminants from the CMS. Carbon

molecular sieve differs from ordinary activated carbons as it has a much narrower range of pore

openings. This allows small molecules such as oxygen to penetrate the pores and separate from

nitrogen molecules which are too large to enter the CMS. The larger nitrogen molecules by-pass

the CMS and emerge as the product gas.


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1.6.0. MOULD DESIGN AREA

FILE

CUSTOMER

INQUARY

PRICE

PROPOSAL

TOOL PRODUCTION

OFFICE

MATERIAL OREDR

(IMPORT)

PREPARE DRAWING/

DESIGN (CAD/CAM)

MATERIAL

RECIEVED

NC - PROGRAM PROFILE TOOL

PREPARED -

TOOL GRINDER

GUIDE PIN / BUSH

MACHINING (LATHE

MACHINE)

GRINDING

(CYLINDRICAL

GRINDER)

MACHINING

(CNC - MACHINE)

ASSEMBLING

SAMPLE TEST


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When the drawings and details of gaskets are received from the customer, the shrinkage is

added to the newly designed mould at the design office by using Auto CAD software. After that,

this drawing is convert into the CNC readable program by using Master CAM software. Then this

G - codes are send to the machinist through a memory chip.

There are 3 - CNC milling machines (HARTFORD VMC 2060) are in the workshop. They are

used to mill gasket moulds. The tools, which are used to cut gasket paths are called profile tools.

They are made according to the shape of the paths. Carbide rods are used to make profile tools

with the help of universal grinder and profile projector.

HARTFORD VMC 2060 BASIC SPECECIFICATIONS

Machine Type : VERTICAL

Control : Fanuc

Number of Axes : 3

X Axis Travel : 2060 mmY Axis Travel : 800 mm

Z Axis Travel : 660 mm

Tool Stations : 20

Spindles : 1

Motor Power : 25 kw

Spindle Speed : 4000 rpm

Machine brand name is Hart Ford and FANUC is the control system, which is feed to this

machine. G - Codes and M - Codes are used to communicate with the machine.

When considering the most commonly use G - Codes, they are,

G00 - Rapid Traverse

G01 - Linear Interpolation (Cutting Feed)

G02 - Circular Interpolation (Clockwise)

G03 - Circular Interpolation (Counterclockwise)

G21 - Input in mm

G28 - Return to reference point

G41 - Cutter compensation leftG49 - Tool length compensation cancel

G80 - Canned cycle cancel

G81 - Drilling

G83 - Peck drilling cycle

G86 - Boring cycle

G90 - Absolute command

G91 - Incremental command

G92 - Programming of absolute zero point

G98 - Return of initial point


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Commonly used M - Codes are,

M03 - Spindle Forward

M01 - Option Stop

M05 - Spindle stopM09 - Coolant off

M30 - Program end

M98 - Subprogram call

M99 - Subprogram cancel

Every CNC machining program has main program. This is the default program for a

machine, which should run in any CNC operation. All other sub programs are amended to this by

using the code M99.

The main program is as follows,

O 0000 ; Program number

G41 , G49 , G80

G91

G28 Z0.0

G28 X0.0 Y0.0

G90

G92 X0.0 Y0.0 Z0.0S1200 ; Spindle speed

M03

F300 ; Feed rate

G00 Z200.0

M98 P100

G91 Z100

M05

M09

G91

G28 Z0.0

G28 Y0.0

M01

M30


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The used moulds are sandblasted to polish the mould paths and cleaned them properly.

SANDBLASTING

Sandblasting is a general term used to describe the act of propelling very fine bits of

material at high-velocity to clean or etch a surface. Sand used to be the most commonly used

material, but since the lung disease silicosis is caused by extended inhalation of the dust created

by sand, other materials are now used in its place. Any small, relatively uniform particles will

work, such as steel grit, copperslag, walnut shells, powdered abrasives, even bits ofcoconut shell.

Due to the dangers of inhaling dust during the process, sandblasting is carefully controlled, using

an alternate air supply, protective wear, and proper ventilation.

A sandblasting setup usually consists of three different parts: the abrasive itself, an air

compressor, and a blaster nozzle. Foretching and small object cleaning, a workstation to hold the

piece of glass is also needed, as is some sort of collector to gather up excess dust. Sandblasting is

primarily used for two somewhat different applications. The first of these is to clean a surface ofanything that may be clinging to it. The second is to either etch or carve designs or words into

glass or a similar material
http://www.wisegeek.org/what-is-copper.htmhttp://www.wisegeek.org/what-is-a-walnut.htmhttp://www.wisegeek.org/what-is-a-coconut.htmhttp://www.wisegeek.com/what-is-an-air-compressor.htmhttp://www.wisegeek.com/what-is-an-air-compressor.htmhttp://www.wisegeek.com/what-is-etching.htmhttp://www.wisegeek.com/what-is-etching.htmhttp://www.wisegeek.com/what-is-an-air-compressor.htmhttp://www.wisegeek.com/what-is-an-air-compressor.htmhttp://www.wisegeek.org/what-is-a-coconut.htmhttp://www.wisegeek.org/what-is-a-walnut.htmhttp://www.wisegeek.org/what-is-copper.htm


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1.7. 0. BOILER AREA

There are two steam boilers which are used to heat the pattern to specified temperature.

The currying temperature is changed gasket to gasket accordingly. Pressure reducing valve is

fitted to every steam supply line to control the temperature.

When considering about the boilers, they are 3 - pass (Reversed flame),

dry - back, horizontally mounted boilers. The steam production rate is 8000PPH at 212oF. They

are usually runs at 15bars. So when we consider about the pressure cutouts, the high fire cutoff is

set to 15bar and when the pressure is goes down to 13bars the boiler is automatically turn on.Safety valve is set to 17 bar.

Air atomizing burner is used to fire the boiler. Heavy oil is used as the fuel.

Two combined steam headers are used to store steam temporary. So the two boilers can

work in harmony.

Boilers are blow down per a shift. And TDS (Total Dissolved solids) are check by using a

TDS meter. The TDS value is kept in between 2000 - 2500 ppm.

When considering about the method of,

1) Raise level of water in boiler in boiler approximately 1 by operating feed pump on hand

control.

2) Insert blow down key and open valve fully until water level drops 2

3) Shut valve and make sure feed pump is switched to auto and water level automatically regained

in boiler.

4) Where two valve are fitted repeat operation for each valve, but blow down 1 inch of water

only.


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When considering about the burner it is a pressure jet oil burner.

1.7.1SEQUENCE OF OPERATION OF OIL FIRED BURNER

On switching on the electricity supply to electric motor turns the fan and the oil pump and

runs for several seconds to purge the boiler of any unwanted gases. After this period a solenoidvalve opens on the high pressure side of the pump to allow oil to be fed to the nozzle, which is so

designed to atomize the oil to the smallest droplets possible where it is mixed with the incoming

forced air from the fan. At this point a spark is provided across the electrodes and the fuel/ air

mixture ignites.

The solenoid valve and photo electric cell and transformer are all controlled by an

electronic control box. A diffuser plate is fitted before the nozzle to form a proper shaped air

pattern and the type of nozzle fitted is also important.

The sequence of operation is important i.e. to purge the boiler of unwanted gases, the

solenoid valve stops oil leaking from the pump to the nozzle when shut down. If the photo electriccell does not see a flame it stops the sequence because if it didnt the boiler combusti on chamber

would be saturated in oil and maybe ignite from the electrode spark.


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1.7.2WEEKLY MAINTENANCE OF THE BOILER

1. Check boiler feed pump and adjust the gland if necessary. The gland should not be unduly

tight. A slight drip at the gland is essential to stop the packing from over heating.

2. Check gas exit temperature by portable temperature gauge, if gauge not fitted.

3. Take water sample for analysis.

4.Give auto clean filter a couple of turns.

5. Check photo - cell of burner by withdrawing while burner is purging prior to firing and

shielding cell from light. The burner should lockout within 5 - 10 seconds of flame being

established.

1.7.3MAINTENANCE TO BE CARRIED OUT EVERY FOUR MONTHS.

1. Dismantle oil filter at burner inlet and clean with paraffin.

2. Remove oil filter from top outlet of oil heater and clean fitting areas.

3. Lubricate the door hinges.

4. Lubricate all motors

5. Dismantle and clean filters on feed pump suction.

6. Dismantle Trist Controls and withdraw the floats from their chambers. Check for any

scale or sediment in the chambers which may cause the float to stick and prevent

operation of the control.

7. Check manhole for leakage.

8. Generally check all valves and pipe work joints.


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2

STATE PHARMACEUTICALS MANUFACTURING

CORPORATION


41/82



2.1.0 About SPMC

The state pharmaceutical manufacturing corporation (SPMC) was established in the year

1987, with the commitment to manufacture quality, effective and safe medicinal drugs at

affordable prices to the public. This pharmaceutical formulation center for the essential drugs is agift by the Government of Japan to the Democratic Socialist Republic of Sri Lanka as a token of

friendship between Japan and the Democratic Socialist Republic of Sri Lanka. Dr. (Mrs.) Gladis

Jayawardene is the originator of the SPMC.

The SPMC is the largest and the leading pharmaceutical manufacture in Sri Lanka which

has a 50, 000 square feet pharmaceutical manufacturing facility. The pharmaceutical

manufacturing facility of the SPMC is equipped with the most modern Japanese & German

machines. The manufacturing facility has an ultra clean atmosphere and the manufacturing

environment is strictly controlled with regard to temperature, humidity, microbial count and

particulate meter. All SPMC products can be categorized as penicillin and non-penicillin drugs

and they comply with the USP (United States Pharmacopeias), & JP (Japan Pharmacopeias), BP

(British Pharmacopeias) standards and SPMCs own standards. Majority is given to the non-

penicillin drugs and manufactured in General Drugs (GD) manufacturing zone. Penicillin drugs

are manufacturing in Penicillin zone.

Since this is a pharmaceutical manufacturing industry, SPMC follows GMPs for

pharmaceutical products specified in WHO document. Based on this document SPMC is used

SOPs for almost every processes. The basic Good Manufacturing Practices (GMP) is as follows

All manufacturing processes are clearly defined

All necessary facilities are provided e.g appropriate trained people,

adequate premises and space, suitable equipment and services. Correct

materials and containers and labels, approved producers and also the

suitable storage and transports.

Operators are trained to carry out the procedure correctly.

Also they always release products to the market with their and logo to ensure identity of

SPMC. Their tablets and capsules carry the letters SPMC and the labels clearly show their famous

and respected logo with characteristics two color bands. Preparation for the health Ministry carry

the letters DHS.

The SPMC consists of main six departments; Production Department, Maintenance

Department, Quality Department, Quality Control Department, Formulation, Research &

Development Department, Finance Department and the Planning, Procurement & marketing

department. All these department are working together to achieve corporations goals.


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Importance and aim of this formulation center can be clearly identify using their Vision &

Mission statements.

Vision

To be an internationally recognized model manufacturing and marketing organization forpharmaceuticals and health care products in South Asia.

Mission

To manufacture safe, effective and affordable medicinal drugs of good quality up to international

standards to the local and international markets.

2.1.1 Function of the Organization

Since SPMC is the only State sector corporation involved in manufacturing

Pharmaceutical in Sri Lanka, it cannot be only profit base industry. Following things can be

presented as the main function of the organization.

Provision of technical assistance for the manufacture and processing of drugs Pharmacological and pharmaceutical research and the standardization of drugs Marketing of drugs

2.1.2 Organization Structure

The SPMC is headed by the chairmen and board of directors appointed by the Minister ofHealth. The General Manager is the chief in command at the SPMC and the respective managers

head the following areas.

Maintenance

Production

Quality control

Formulation Development

Administration

Accounts

Planning and production

Under each manager there are assistant managers, executives and workers for the each of

the development. This is a semi government organization which is being funded by its own

performance.


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Chairman and board of directors

Workin director

General Mama er

Production

Manager

Maintenance

Manager

Formulation

and

developmen

Quality

control

Mana er

Planning and

Procurement

Mana er

Asst. Manager

(Sales

Promotions

Administration

Officer

Management

Accountant

Asst.

Production

Mana er

Pharmaceutica

l Technologist

Senior

process

Asst.

Process

Assistants

Asst.

Engineer

Mechanical

Senior Maint.

Receptionist

Typist

Laborers

Driver /

Porter

Maint. Tech.

Engineering

Asst.(mech)

Asst.

Engineer

Engineering

Asst.(elec)

Senior Maint.

Maint. Tech.

Pharmaceutical

technologist (Plannig)

Planning

Assistants

Stores

Assistants

Asst. Formulation

and development

Mana er

Technical

Asst.

Asst. Chemist

Asst.Quality

controlMana er

Quality control

Officer

Quality control

Asst.

Accounts Asst.

Accountant


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2.1.3 SPMC Product List

Aluminium Hy.Tab. BP 500mg Amoxicillin Tab. USP 125mg

Amoxicillin Cap. BP 250mg Amoxicillin Cap. BP 250mg. - Bliter

Amoxicillin Cap. BP 500mg Amoxicillin Cap. BP 500mg. - Blister

Ascorbic Acid Tab. BP 100mg Atenolol Tab. BP 50 mg (Blister)

Benzhexol Tab. BP 2mg Bisacodyl Tab. BP 5mg

Carbamazepine Tab. BP 200mg Chloramphenicol Cap. BP 250mg

Chloroquine Phos. Tab. BP 250mg Cimetidine Tab. BP 200mg

Cloxacillin Cap. BP 250mg Cloxacillin Cap. BP 500mg. - Blister

Cloxacillin Cap. BP 500mg Co-Trimoxazole Tab. BP 480mg

Diclofenac Sodium Tab.USP 50mg Diethylcarbamazine Tab. BP 50mg

Erythromycin Stearate Tab. BP 250mg Folic Acid Tab. BP 5mg

Frusemide Tab. BP 40mg Famotidine Tab. USP 20mg ( Blister )

Indometacin Cap. BP 25mg Mebendazole Tab. USP 500mg

Mebendazole Tab. USP 500mg Sachet Mebendazole Tab. USP 100mg

Metformin Tab. BP 500mg Paracetamol Tab. BP 500mg. (Blister)

Paracetamol Tab. BP 500mg Paracetamol Tab. BP 500mg

Phenoxy.penicillin Tab. BP 125mg Phenoxy.penicillin Tab. BP 250mg

Prednisolone Tab. BP 5mg Prednisolone Tab. BP 5mg

Propranolol Tab. BP 40mg Rifampicin Cap. BP 150mg

Salbutamol Tab. BP 2mg Salbutamol Tab. BP 2mg

Salbutamol Tab. BP 4mg Theophylline E.R. Tab. 125mg

Theophylline E. R. Tab. 300mg Trifluoperazine Tab. BP 5mg

Verapamil Tab. BP 40mg Vitamin B Complex Tablets

Vitamin B Compound Strong Tab. BPC


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2.2 MAINTENANCE DEPARTMENT

Maintenance Department plays a key role in the operation of the SPMC and its functions

as follows.

Operation of utility section

- Raw water supply, Purification & Distribution

- De-Ionized water supply

- UV sterilization of water

- Fire water supply

- Compressed air supply

- Steam generation & supply

- Emergency power generation

- Air conditioning

- Maintain effluent treatment plant

- Daily routing

Maintenance and repair of machinery, buildings and vehicles

Supply of Engineering services

Since this is GMP (Good Manufacturing Practices) conserned organization the utility

section is situated separate from manufacturing area and utilities are supplied via pipe lines such

amanner that the network of these lines designed properly in separate area from production called

Cat Walk area. There are separate bunches of pipe lines to general drug zone, penicillin zone, E

zone & F zone.

Other than main functions Maintenance Department carry out machine maintenance works as

following ways.

Planned Preventive Maintenance

Breakdown Maintenance

Corrective Maintenance


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2.2.1. AIR CONDITIONING

Air conditioning is the process of altering the properties ofair(primarily temperature and

humidity) to more favorable conditions. More generally, air conditioning can refer to any form of

technological cooling, heating, ventilation, ordisinfection that modifies the condition of air.

Fig.2.2.1 Air conditioning cycle

The refrigerant comes into the compressor as a low-pressure gas, it is compressed and then

moves out of the compressor as a high-pressure gas.

The gas then flows to the condenser. Here the gas condenses to a liquid, and gives off its

heat to the outside air.

The liquid then moves to the expansion valve under high pressure. This valve restricts the

flow of the fluid, and lowers its pressure as it leaves the expansion valve.

The low-pressure liquid then moves to the evaporator, where heat from the inside air is

absorbed and changes it from a liquid to a gas.

As a hot low-pressure gas, the refrigerant moves to the compressor where the entire cycle

is repeated.

Note that the four-part cycle is divided at the center into a high side and a low side This

refers to the pressures of the refrigerant in each side of the system.
http://en.wikipedia.org/wiki/Airhttp://en.wikipedia.org/wiki/Temperaturehttp://en.wikipedia.org/wiki/Humidityhttp://en.wikipedia.org/wiki/HVAChttp://en.wikipedia.org/wiki/Disinfectionhttp://en.wikipedia.org/wiki/Disinfectionhttp://en.wikipedia.org/wiki/HVAChttp://en.wikipedia.org/wiki/Humidityhttp://en.wikipedia.org/wiki/Temperaturehttp://en.wikipedia.org/wiki/Air


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Types of Air conditioning systems

1. Central Air Conditioning Systems.

Use these systems for applications where several spaces with uniform loads will be served

by a single apparatus and where precision control of the environment is required. Cooling coilscan be direct expansion or chilled water. Select air cooled or evaporative condensers, cooling

towers, and ground-loop systems based on life cycle economics considering operating efficiencies

and maintenance costs associated with outdoor design conditions and environment, e.g., high

ambient temperatures and dusty conditions could adversely impact the operation of air cooled

condensers. Consider temperature rise of chilled water supply when selecting chilled water coils,

especially for applications requiring precision humidity control.

2. Unitary Air Conditioning Systems.

These systems should generally be limited to loads less than 100 tons. Unitary systems arepackaged in self-contained or split configurations. Self-contained units incorporate components

for cooling or cooling and heating in one apparatus. Thermostatic expansion valves are preferred

over capillary tubes and orifices for refrigerant control when available as a manufacturer's option

since expansion valves provide better superheat control over a wide range of operating conditions.

Split systems may include the following configurations:

a) Direct expansion coil and supply fan combined with a remote compressor and condensing coil;

or

b) Direct expansion coil, supply fan, and compressor combined with a remote condenser, coolingtower, or ground-loop system..

These systems generally have lower first cost than central systems but may have higher

life cycle costs. If part load operation is anticipated for a majority of equipment operating life,

consider multiple unitary equipment for superior operating efficiencies and added reliability.

3. Room Air Conditioning Units.

These units are self-contained units serving only one space. These units are typically

referred to as window or through-the-wall type air conditioners.

4. Built-up Systems

These systems consist of individual components assembled at the building site. Generally,

use them when a large volume of air is handled. These systems may be used as remote air

handling systems with a central cooling plant. unitary air handling units. Determine the number of

air handling units by an economic division of the load, considering: (a) the value of space

occupied by equipment; (b) the extent of ductwork and piping; (c) the multiplicity of control,

maintenance, and operating points; and (d) energy conservation factors.


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In the pharmaceutical zone, the single duct central air conditioning system is used.

Air Conditioning Method

In the pharmaceutical zone, the single duct air conditioning system is adopted. Since

dehumidifying control is required, re-heating control is performed by using the heating coil in theair conditioning unit. In the system, return air is mixed with outdoor air, and then cooled to the

required temperature, i. e. below the dew point at the surface of the cooling coil, by means of the

cooling. Then, the moisture in the air is condensed to water at the surface of the cooling coil. In

this way, the mixed air is dehumidified.

This cooled air is too cold for proper air conditioning of the rooms. So the cooled air is re-

heated by using the heating coil. Re-heating performance of the heating coil is adjusted according

to the temperature of the junction of return air from each room, which is nearly equal to the

average of temperature of the rooms.

Cooling and re-heating are performed in sequence in this re-heating control system. This

inevitably requires large energy consumption. Therefore, the purpose of energy conservation, this

system is designed so that air conditioning without humidity control, namely cooling only, can be

performed by switching off the heating coil and by controlling the cooling coil performance

according to the temperature of return air for a case where no strict humidity control is required.

Specific Humidity and Relative Humidity.

Air which contains no moisture is called dry air. The air around us is a mixture of dry

and moisture, and air which contains moisture in the way is called humid air. When the number

of kilograms of moisture contained in 1kg of dry air is expressed numerically, it is called specific

humidity.

Air can only contain a limited amount of moisture. When air contains maximum amount of

moisture and can take in no more, it is said to be saturated, and air in this state is saturated

humid air.

Humidity can also be expressed in percent by comparing the moisture in air against the

amount of moisture in saturated humid air at the same temperature. This is called relative

humidity, and is expressed in percent.

Even if the amount of moisture in the air is exactly the same, the ratio of moisture which

can be absorbed increases in proportion to the temperature, so relative humidity decrease.


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When considering the main parts of the central air conditioning system, they are Chiller, Cooling

tower and Air handling unit.

CHILLER

Chillers are a key component of air conditioning systems for large buildings. They

produce cold water to remove heat from the air in the building.

The SPMC chiller plant has the following specifications.

Power Source : 3 - phase, 400V, 50Hz

Output Compressor : 2 30 kwRunning Current : 111A

Refrigerant : R22 2 15 kg

Design pressure : High 25kgcm-2 Low 13kgcm-2

When considering the main parts of the chiller they are,

1. Compressor.

2. Condenser.

3. Evaporator.

4. Expansion valve


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And also the refrigerant, which is the working blood of the system.

1. Compressor

The reciprocating compressor is the most widely used type, being employed in all field of

refrigeration. It is especially adaptable for use with refrigerants requiring relatively smalldisplacement and condensing at relatively high pressures.

When considering the SPMC chiller unit, it consisted two reciprocating compressors. Each

compressor consisted with 6 cylinders and R22 is the refrigerant that used.

2. Condenser

The function of a condenser are to desuperheat the high-pressure gas, condense it and also

sub cools the liquid. Heat from the hot refrigerant gas is rejected in the condenser to the

condensing medium-air or water. Air and water are chosen because they are naturally available.

Their normal temperature range is satisfactory for condensing refrigerants. Like the evaporator,the condenser is also a heat exchange equipment.

According to the maul of the SPMC chiller it has shell and cross fine tube condenser

COOLING TOWER

The cooling tower is used in a conjunction with the water-cooled condenser. Water in

passing through the condenser water tubes only gets warmed up but does not get contaminated. It

can, therefore, be used again, after cooling. The cooling tower cools the warm water for

recalculating it in the condenser. It is thus water-conservation equipment. The heat removed by

the refrigeration system from the space or product to be cooled is ultimately thrown to the

atmosphere through the cooling tower in a water-cooled condenser system. A cooling tower is a

wind-braced housing or shell (wood, concrete, brick, or metal) with filling on the inside. Cooling

is usually from 4 to 100F of wet-bulb temperature.


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Types of Cooling Towers

Cooling towers are broadly divided into two classes:

1. The natural-draft or atmosphere tower, which the air movement through the tower depends

upon natural wind movement.

2. The mechanical-draft tower through which air is drawn (or forced) by fans.

Induced-draft

Forced-draft

The SPMC have mechanical - draft cooling towers for central air conditioning system.

3. Evaporator

When the liquid refrigerant reaches the evaporator its pressure has been reduced,

dissipating its heat content and making it much cooler than the fan air flowing around it. This

causes the refrigerant to absorb heat from the warm air and reach its low boiling point rapidly.

The refrigerant then vaporizes, absorbing the maximum amount of heat.

This heat is then carried by the refrigerant from the evaporator as a low-pressure gas

through a hose or line to the low side of the compressor, where the whole refrigeration cycle is

repeated.


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In chiller unit the evaporator cools the water, which is required for the cooling coil. The

SPMC chillers have dry expansion, shell and corrugated tube evaporator

4. Expansion valve.

The expansion valve removes pressure from the liquid refrigerant to allow expansion orchange of state from a liquid to a vapor in the evaporator.

The high-pressure liquid refrigerant entering the expansion valve is quite warm. This may be

verified by feeling the liquid line at its connection to the expansion valve. The liquid refrigerant

leaving the expansion valve is quite cold. The orifice within the valve does not remove heat, but

only reduces pressure. Heat molecules contained in the liquid refrigerant are thus allowed to

spread as the refrigerant moves out of the orifice. Under a greatly reduced pressure the liquid

refrigerant is at its coldest as it leaves the expansion valve and enters the evaporator.

Pressures at the inlet and outlet of the expansion valve will closely approximate gauge pressures at

the inlet and outlet of the compressor in most systems. The similarity of pressures is caused by the

closeness of the components to each other. The slight variation in pressure readings of a very few

pounds is due to resistance, causing a pressure drop in the lines and coils of the evaporator and

condenser.

Two types of valves are used on machine air conditioning systems:

Internally-equalized valve - most common

Externally-equalized valve special control

AIR HANDLING UNIT

Air handling unit (AHU) is the primary equipment in an air handling system, which handle

and conditions the air (Filtering and dehumidifying) and distribute it to various condition space. In

AHU the required amount of outdoor and recalculating air are mixed and conditioned. The

temperature of the discharge air is maintained within pre-determine limits by means of suitable

control mechanism. This mixed air, is provided with motive force and is distributed to various

conditioned spaces through duct works.


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RUNNING SPECIFICATIONS OF CHILLERS IN SPMC

Compressor discharge pressure : 15 - 18 kg/cm2

Difference between discharge pressure : Under 1 kg/cm2

of right and left compressors

Suction pressure of refrigerant : Within 3.5 - 6 kg/cm2

Difference between suction pressure : Under 0.5 kg/cm2

of right and left compressors

Cooling water in flow rate : 664 l/min

Chilled water in flow rate : 520 l/min

Cooling water outlet temperature : 30OC - 40OC

Cooling water inlet temperature : 25OC - 35OC

Chilled water outlet temperature : 5OC - 12OC

Chilled water inlet temperature : 10OC - 152

OC


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2.2.2 RAW WATER TREATMENT, SUPPLY & PURIFICATION SYSTEM

Water treatment process consists of raw water purification system and de-ionized water

system. Here water is purified to two stages as pharmaceutical water which is used for

manufacturing of drugs and non pharmaceutical water which is used for other purposes includingdrinking.

BLOCK DIAGRAM FOR RAW WATER PURIFICATION AND SUPPLYING SYSTEM

EXPLANATION OF THE WATER TREATMENT SYSTEM

- The raw water is sent to the carbon filter by the water deionizer pump. The water

deionizer pump is controlled by the float switch of the deionizer water tank.

- The water deionizer pumps automatically operate alternatively every time when the

tank is filled with water.

- The removal of residual chlorine, decolorization and deodorization are made by the

carbon filter and then the raw water is sent to the deionizer. The water flow rate can be

measured by a flow meter.

MUNICIPAL

WATER

UNDERGROUND

SUMP

SAND FILTER FILTERED

WATER TANK

ELEVATEDWATER TANK

ULTRA- VIOLET

STERITRON

NON-

PHARMACEUTICAL

WATER

CARBONFILTER

WATERSOFTNER

DEIONIZER

PHARMACEUTICAL

WATER


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- The raw water sent to the deionizer is put to ion - exchange and stored in the deionized

water tank. A conductivity monitor always monitors the treated water of deionizer.

- The treated water in the deionizer water tank is sent by the deionizer water circulation

pump. The deionizer circulation pump is controlled by a 24-hour timer.

- The treated water sent by the deionized water is sterilized when it passes through the

ultra violet sterilizer.

SAND FILTER (DEPTH FILTER)

The unit consists of 03 filtration layers.

1- Upper-large grain-size layer

2- Middle finer grain-size layer

3- Lower finer grain-size layer

Water flows downwards

Insoluble large particles are caught by lower filtration layers with finer grain size

Finer particles are caught by lower filtration layers with finer grain size

The whole filtration system works effectively, enabling the stable quality water to be supplier over

many hours.

The turbid elements caught by each layer are washed away by the appropriate backwash and

rinsing process. (This keeps the filtration layers are good condition)

Good water quality can be obtained by making the backwash every day. The backwash time

becomes necessary according to;

The turbidity of water

Its volume used

Flow rate

If the backwash mechanism gets mal-functions it may degrader the quality of disposed water,

reduce its volume and lower the function of the filtering material.

THE WORKING OF MIXEDBED DEIONIZER

Culligan Mixed-Bed Deionizer will remove essentially all ionizable impurities from

water. The mineral free product water is always of uniform high quality, cycle after cycle, and is

suitable for the most exacting needs of industry. The deionized water will normally contain less

than 0.5 ppm of dissolved solids and will have a specific resistance higher than 1,000,000 ohms.

Deionization requires the use of two ion exchange resins, Cation resin and Anion resin.

Cation resin will remove from water all positively charged metallic ions (called cation ) such ascalcium, magnesium, sodium, potassium, etc. Anion resin will remove from water all negatively


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charged ions (Called Anions) such as chloride, sulfate, bicarbonate, nitrate, silicon, carbon

dioxide, etc. Thus, when water passes through these two resins, all ionized solids are retained by

the resins beds and only pure water is left. When these two resins are mixed together as one

homogeneous resins bed in a single tank, superior water quality is obtained.

Resin beds are able to exchange and retain a fixed quality of dissolved ions. Thischaracteristic is defined as capacity. When the beds capacity has been all used, no further

exchange can take place and the resin is said to be exhausted. The resin can be returned to its

originalstate by a process called regeneration. Cation resin is regenerated with acid and anion

resin is regenerated with caustic soda.

Mixed-Bed Deionizer consists of a single ion exchange tank in which fully regenerated

cation and anion resins are uniformly mixed together. As the raw water passes down through the

resin bed, the dissolved ions are removed and retained in the resins. When all the bed is exhausted

the resins are regenerated and the deionizing process starts again.

The exhausted bed is first backwashed up flow to remove any dirt collected on the top ofthe bed, to loosen any packed resin, separate the resins in two independent layers, with cation

resins on the bottom, anion resin on the top, and a distinct interface

Documents

Training reports GIT at IET