TABLE OF CONTENT
1. Obje Object ctiv ive e 2. Scope 3. Responsibili Responsibility ty (Client (Client and manufacturer) manufacturer) 4. RS (ser (ser Re!uir Re!uiremen ementt Speci"cati Speci"cation) on) #. $ac%i $ac%ine ne descr descrip iptio tion n &. 'ec%nical speci"cation speci"cation of of sub componentsbr componentsbrou%t ou%t out items. items. *. Speci"c Speci"catio ation n of of +utoma +utomation tion.. ,. $ac%ine $ac%ine operati operation on control control t%ro t%rou% u% -C /. 0etails 0etails of poe poerr consum consumptio ption n 1. $aterial $aterial of constru constructio ction n of of compo componen nentt 11. 'est certi" certi"cate catesns snspect pection ion repo reports rts 12. Surface Surface +rea +rea of t%e produ product ct contac contactt parts parts 13. 13. rief rief -ro -roces cess s 0esc 0escri ripti ption on 14. 14. Safety Safety5n 5nter terlo loc6s c6s+l +lar arms ms messa messae es s 1#. 1#. oad oad calib calibra rati tion on c%ar c%artt 1&. 1&. ubr ubrica icatio tion n re! re!uir uireme ements nts 1*. 1*. 7+' pr proced ocedur ure e 1,. 1,. C%an C%ane e contr control ol pro proced cedur ure e 1/. +ppendi8 1.0 OBJECTIVE:
'o 'o desin9 enineer9 enineer9 and supply t%e Cadmac% C-0553* station it% i aye ayerr attac% attac%men mentt as per c:$c:$- and c:;c:;- uid uideli elines nes and and to prov provide ide assu assura ranc nce e t%at t%at t%e t%e mac% mac%in ine e is manu manufa fact ctur ured ed as per per t%e t%e RS RS and and it complies it% t%e Scope of Supply. 'o 'o prove t%at eac% eac% operation operation proceeds proceeds as per t%e desin speci"cation speci"cation and t%e tolerances prescribed t%ere in t%e document9 are t%e same at utmost
transparency.
2.0 SCOPE:
'%e scope of t%is !uali"cation document is limited to t%e 0esin >uali"cation of Cadmac% C-0553* station it% i ayer +ttac%ment for $s S< imited9 in 0aman. '%is !uali"cation document is part of a validation activity for t%e Cadmac% C-0553* station. >uali"cation of support utilities is not it%in t%e scope of t%is !uali"cation document. '%e e!uipment s%all be used for compressin t%e poder into tablets. '%e e!uipment s%all operate under dust free environment and conditions as per t%e :$- re!uirements.
3.0 RESPONSIBILITIES: 3.1 CLIENT: 3.1.1 'o provide t%e RS for t%e e!uipment. 3.1.2 'o perform t%e 7actory +cceptance 'est (7+'). 3.2 MANUFACTURER: 3.2.1 'o desin9 enineer and provide t%e complete tec%nical details of t%e e!uipment pertainin to its desin !uali"cation vi?.
3.2.1.a 3.2.1.b t%eir
$ac%ine overvie9 Speci"cations of t%e sub5components bou%t out items9 and
ma6e9 model = !uantity9 and bac6up records broc%ures9 3.2.1.c 0etails of tilities9 3.2.1.d $aterial of construction of all components 3.2.1.e rief process description 3.2.1.f Safety features. 3.2.2 'o facilitate t%e client for t%e 7actory acceptance test of t%e mac%ine at t%eir or6s site. 3.2.3 'o con"rm t%e safe delivery of t%e e!uipment to t%e user site. 3.2.4 'o ensure t%at no un5aut%ori?ed and or unrecorded desin modi"cations s%all ta6e place. f at any point in time9 any c%ane is desired in t%e mutually areed desin9 C%ane control procedure s%all be folloed and documented.
3.2.# 'o ensure t%e proper installation and commissionin of t%e e!uipment. 4.0
URS ( User Requre!e"# S$e%&%'#") :
-lease refer attac%ed A""e*ure Re!uirement Speci"cation.
N.
+,-AN-03
for
t%e
ser
/.0 MACINE +ESCRIPTION /.1 Pr%ess Equ$!e"# +es%r$#"
'%e Cadmac% C-0553* station it% i ayer +ttac%ment9 a double rotary tablet press9 is a versatile mac%ine in t%e rane of tablettin. t is also
incorporated it% t%e force5feedin arranement9 ubrication (ntermittent @ Continuous)9 electromanetic clutc% and -rorammable oic Controller. '%e i ayer attac%ment facilitates in producin tin colour tablets. Complete mac%ine can be divided in folloin sub sectionsA #.1.1 -oder feedin unit (BS = RBS) #.1.2 -oder 'ransfer unit (BS = RBS) #.1.3 0rive unit9 'urret and Compression unit #.1.4 ei%t 0o?er (BS = RBS) #.1.# Bydraulic -oer -ac6 +ssembly. #.1.& 'ablet disc%are unit (BS = RBS)
/.1.1 Per Fee" U"# (LS RS) : '%is comprises of t%e folloin D #.1.1.a Bopper it% utterEy valve (BS = RBS) #.1.1.b -oder level sensor (BS = RBS)
#.1.1.a Bopper it% utterEy valve (BS = RBS) +n SS 31& Bopper of capacity 1, iters rests on top of t%e mac%ine %ic% %olds t%e poder in it and delivers to t%e feedin assembly t%rou% a butterEy valve %ic% controls t%e Eo of t%e poder beteen t%e Bopper and t%e 7eedin assembly. t comprises of a Eap9 %ic% can be operated usin a 6nob. n case of i ayer tablets9 bot% t%e %oppers s%all contain diFerent colour poderranules. #.1.1.b -oder evel Sensor (BS = RBS)A 5 '%is is set on a si%t lass "t to t%e %opper. '%e settin is done usin to adjustable nuts. +s soon as
t%e poder in t%e %opper drops don t%e level9 t%e sensor senses t%e same and ives t%e respective sinal to t%e -C and stops t%e mac%ine. /.1.2 Per Tr'"s5er U"#: 6 '%is comprises of t%e folloin D #.1.2.a nlet Connector (BS = RBS) #.1.2 b 7orce 7eeder +ssembly (BS = RBS)
#.1.2.a nlet Connector (BS = RBS) t is a SS 31& connector9 %ic% lin6s t%e Bopper and t%e 7orce feeder.
#.1.2.b 7orce 7eeder +ssembly (BS = RBS) t comprises of #.1.2.b.i 7orce 7eeder #.1.2.b.ii 'ail over die9 scrappers and feeder #.1.2.b.iii Go??le outlet for suction. #.1.2.b.i. 7orce 7eeder '%e force feeder %as to counter rotatin paddles of SS 31& 9 driven by reduction earbo8 and variable fre!uency +C drive motor. '%e pressin material enters t%e feeder in t%e middle beteen t%e to paddles. it% t%e feeder in t%e H$+G+ $O0;I9 t%e force feeder is operated for initial "llin prior to rotatin t%e mac%ine and in H+'O $O0;IJ t%e force feeder ill run alon it% t%e mac%ine. %ile mac%ine is in production9 alays put t%e feeder in H+'O $O0;I. #.1.2.b.ii 'ail over die9 scrappers and feeder '%e tail over die is an essential feature of t%e %i%5speed tablet press. '%e function of t%e tail over die is to 6eep t%e "lled die covered until t%e last moment before t%e upper punc% enters t%e die. 7ailure to 6eep t%e die covered ill result in ranules spillin out of t%e die it% subse!uent variation of t%e tablet ei%t. '%e tail over die is "tted freely over t%e turret die table and is pressed aainst t%e die table by sprin action. ;nsure t%at t%e bottom surface of t%e tail over die rests Eat and matc%es it% t%e die table.
'%e sprin5loaded scrappers are inserted in t%e scrapper support brac6et and tail over die respectively. '%e sprins press t%e scrappers aainst t%e turret die table to scrap oF. t%e tablettin poder
#.1.2.b.iii Go??le outlet for suction '%is comprises of a -
#.1.3.a 0rive unit + main motor of *.# B- drives a very %i% reduction earbo8 unit usin an electromanetic clutc% and a timin belt. '%e earbo8 unit consists of a -%osp%orus bron?e (S+;&#) orm %eel and a orm s%aft of S+; ,&2 (it% case %ardenin %avin #, D &2 BRC). '%e orm %eel s%aft %olds t%e -inion. '%e turret %as an internal %elical rin9 %ic% mes%es e8ternally to t%e pinion. '%e rotation of t%e pinion is responsible for turret motion. '%us9 C-0 D D 3* stations is purely eccentric drive. N.B.: 6 T9e r#'#" 5 CP+6II63 s#'#" s %;%<se. #.1.3. b 'urret '%is tool %oldin body is a 3 piece structure %avin t%e center die table of SS 31& and t%e pper and oer piece of Cast iron of rade 7:52&. '%e upper piece %olds t%e upper punc%es9 %ic% rests on t%e upper cam trac6s it% t%e cam plate. Similarly9 t%e loer piece %olds t%e loer punc%es t%at travel on t%e loer cam trac6s and do?er. '%e 0ies lie in t%e die cavities provided in t%e die table it% t%e %elp of die loc6in scre assembly. '%e loer punc%es are secured usin punc% %oldin device comprisin of bra6e plu9 anti5turnin sprin strip and button %ead scre. #.1.3.c Compression nit D '%is comprises of #.1.3.c.i pper $ain -ressure Roll +ssembly (7ront and Rear) #.1.3.c.ii oer $ain -ressure Roll +ssembly (7ront and Rear) #.1.3.c.iii pper -unc% -enetration +ssembly ($ain D 7ront = Rear)
#.1.3.c.iv
'ablet '%ic6ness +ssembly ($ain 5 7ront and Rear)
#.1.3.c.i pper $ain -ressure Roll +ssembly (7ront = Rear) t comprises of a Roll Center9 -ressure Roll and -ressure Roll -in. '%e Roll Center %olds t%e -ressure Roll and is loc6ed usin ;8ternal Circlips. '%e rotation of t%e Roll is ta6en care by 2 Go. cylindrical roller bearin (GK5 31). #.1.3.c.ii. oer $ain -ressure Roll +ssembly (7ront = Rear) t comprises of a Roll Center9 -ressure Roll and -ressure Roll -in. '%e Roll Center %olds t%e -ressure Roll and is loc6ed usin ;8ternal Circlips.'%e rotation of t%e Roll is ta6en care by 2 Gos. cylindrical roller bearin (GK5 231). #.1.3.c.iii pper -unc% -enetration +ssembly ($ain D 7ront = Rear) '%is is t%e assembly9 %ic% is responsible for t%e entry %ei%t of t%e upper punc% in t%e die. %enever t%e %eel of upper punc% penetration is rotated9 t%e entire upper pressure assembly it% t%e carrier alon it% t%e loer pressure assembly is moved up and don. +lays care needs to be ta6en to set t%e upper punc% penetration initially and only t%en t%e t%ic6ness. #.1.3.c.iv 'ablet '%ic6ness +ssembly ($ain D 7ront = Rear) '%is is t%e assembly9 %ic% is responsible in decidin t%e tablet t%ic6ness. '%e upard and donard movement of t%e loer pressure carrier assembly varies t%e t%ic6ness. /.1.4 =e9# +>er (LS '" RS) '%is assembly is responsible for adjustin t%e ei%t of t%e tablet by varyin t%e dept% of "ll. '%e dept% of "ll is adjusted by t%e upard and donard movement of t%e ei%t adjustin %ead t%rou% a do?er adjustin scre it% t%e %elp of dial. /.1./ ?r'u;% Per P'%< Asse!@;? '%is system controls t%e safety overload mec%anism9 %ic% overns t%e ma8imum pressure9 level9 at %ic% particular tablets are bein made. '%e oil reservoir for t%is system is located in front corner it%in loer cabinet.
t can be accessed by removin t%e loer side uard (B). '%e oil level in t%e reservoir s%ould be c%ec6ed reularly t%rou% t%e oil level indicator. /.1. T'@;e# s%9're u"# '%is comprises of5 #.1.&.a ;jection Cam (BS = RBS) #.1.&.b 'ablet ta6e oF plate assembly (BS = RBS) #.1.&.c 'ablet disc%are c%ute (BS = RBS).
#.1.&.a. ;jection Cam (BS = RBS) '%e loer punc% lides on t%e ejection cam and ejects t%e tablet. '%e %ei%t of t%e ejection cam needs to be set in suc% a ay t%at t%e tip of t%e loer punc% is sli%tly above t%e die so as to avoid tablet5c%ippin problem. n case of i ayer operation9 t%e ejection cam and "ll cam of t%e BS are removed. '%is is done to facilitate t%e "llin of t%e second layer on t%e initial layer.
#.1.&.b 'ablet ta6e oF plate assembly (BS = RBS) +s soon as t%e tablet is ejected out it stri6es t%e tablet ta6e oF plate assembly9 %ic% directs t%e tablet to t%e disc%are c%ute. Care s%ould be ta6en so t%at t%e tip of t%e loer punc% does not stri6e t%e tablet scrapper assembly. n case of i ayer operation9 t%is assembly is present on t%e RBS feeder only as t%ere is no ejection on BS. #.1.&.c 'ablet disc%are c%ute (BS = RBS) t is made of SS 31& it% acrylic cover. 'ablets slide out t%rou% t%is c%ute to t%e container. n case of i ayer operation9 only one disc%are c%ute is present i.e.9 on t%e RBS.
.0 Te%9"%'; s$e%&%'#" 5 su@ %!$"e"#s - @u9#6u# #e!s.
.0 S$e%&%'#" 5 Au#!'#" Automation A.C.Drive for Main Motor A.C.Drive for Fee'er Motor !)C (yste* MM1 Tou4h s4reen
Make Mitsubishi Mitsubishi Mitsubishi Mitsubishi
Specification Type FR E 500 - 5.5 K Rating 7.5 !" # !hase" $%5 & Type FR ( 500 - 0.75 K Rating % !" # !hase" $%5 & Type F+, $ MR / , AD / ,DA" $ 'igita 1 2 3 , Anaog 1 2 3 Type F $0 63T )D 5.7 8 Coour
Speci"cation of prorammable loic control systems A Make : MITSUBHISHI, Catalogue No. FX2N !" M# $S % UA u*ber of 1nput23utput u*ber of 1nput23utput )ine !o9er 1nrush 4urrent 1nput 4ir4uit type 3utput 4ir4uit type 3perating te*perature (torage te*perature 3perating hu*i'ity &ibration
,$ 1nputs ,$ outputs %00 - ,$0 & AC 502:0 ; 0., A ,$ DC sin< 2 sour4e MR - E( 2 =) >Reay output? o o 3 o / 0 to 553 4 > / #, F to %#% F ? A*bient o o 3 o - ,0 C to /70 C> -$ F to /%5 F? A*bient 5 @ to 5 @ reative hu*i'ity > on- 4on'ensing? 3perating %0 to 57 B" 0.0#5 **. af ,
A*pitu'e - 57 to %50 B. $. n 2 se4 -- a44eeration , (ho4< Resistan4e E : - ,- ,7" %% M(" %$7 *2se4 --a44eeration. Agen4y 4ertifi4ation CE" =) 2 4=)" =) 50. CE 4o*paint for a appi4abe 'ire4tives. Ter*ina s4re9 torue 0.# to 0.: * 1.e. # to : Kgf - 4*
.0 M'%9"e $er'#" %"#r; #9ru9 PLC Sitc% on t%e mains9 LelcomeM screen ill be displayed ;nter valid passord9 L$ain menuM screen ill be displayed '%ree levels of passord ill be provided as follosA a) Operator evel b) Supervisor evel c) $anaer evel -ress mac%ine control touc% button9 detailed L$ac%ine control menuM screen ill be displayed -ress turret control touc% button9 detailed L'urret control menuM screen ill be displayed -ress feeder control touc% button9 detailed L7eeder control menuM screen ill be displayed -ress compaction force touc% button9 detailed LCompaction force menuM screen ill be displayed -ress lubrication control touc% button9 detailed Lubrication control menuM screen ill be displayed • • •
•
•
•
•
•
-ress mac%ine status touc% button9 detailed L$ac%ine status51 menuM screen ill be displayed -ress recipe manaement touc% button9 LRecipe passordM screen ill be displayed -ress batc% data touc% button9 detailed Latc% data menuM screen ill be displayed -ress tec%nical data touc% button9 detailed L'ec%nical data menuM screen ill be displayed $ore detail about mac%ine operation control t%rou% -C is as per t%e attac%ed or6in nstruction $anual of -C 'ouc% Screen. N#eA Separate nstruction $anual is attac%ed as anne8ure •
•
•
•
•
.0
+e#';s 5 $er %"su!$#" M#r M'"
R'#e s$e%&%'#"
•
Feeer (R..)
41# *.# 14.#
•
Bp +mperae
Feeer (L..)
41# .2# .#,
•
Bp +mperae •
41# .2# .#,
Per $'%<
41# 1 1.,
'otal poer consumption for main mac%ineA / N
10. 0 M'#er'; 5 C"s#ru%#" 5 %!$"e"#
+es%r$#" 'urret a) pper piece b) 0ie table -ressure Roll orm S%aft
L%'#" pper cabinet
oer
Roll Carrier $ain drive :ear o8 $ain drive :ear o8
orm S%aft
7eeder drive :ear o8 7eeder :ear o8 pper Cabinet 7eeder %ousin Roof Gear die table oer cabinet
-addle for force feeder Bopper 0isc%are c%ute oer uards
11.0
7:52& SS 31&
orm %eel ($ain 0rive)
orm %eel (7eeder 0rive) 7eeder %ousin
MOC
Tes# %er#&%'#es - I"s$e%#" re$r#s.
OBGS S+; ,&2 it% case %ardenin %avin #,5&2 BRC -%osp%orus ron?e (S+;&#) $ild Steel -%osp%orus ron?e :un $etal SS 31& SS 31& SS 31& SS 34
S.N&.
'$SC#I(TI&N
%%.% %%., %%.# %%.$ %%.5 %%.: %%.7 %%. %%. %%.% %%.% %%.%, %%.%# %%.%$ %%.%5 %%.%: %%.%7 %%.% % %.% %%.,0 %%.,% %% ., , %%.,# %%.,$ %% ., 5 %%.,: %%.,7 %%., %%., %%.#0 %%.#% %%.#, %%.##
Main Drive Motor For4e Fee'er Motor For4e Fee'er Motor y'.!o9er !a4< Motor AC Freuen4y Drive >Main Motor? AC Freuen4y Drive >Fee'er Motor? !)C G MM1 Ee4tro*agneti4 Cut4h y'.A44u*uator y'.!ressure6uage )ubri4ation !u*p !.!.1 !ressure (ensor %00ar !o9er )eve (ensor Digita &ot *eter Digita A*p. Meter M.3.C. of Turret M.3.C. of Die Tabe (( #%:) M.3.C. of !ressure Ro M. 3.C . o f Ru bb er e o 9 M.3.C. of !a''e (( #%:) M.3.C. of opper (( #%:) M. 3.C . of Dis 4h arg e Ch ute (( #% :) M.3.C. of )o9er 6uar' M.3.C. of Fee'er ousing M. 3.C . of or* hee >Mai n? M.3.C. of or* hee >Fee'er? M.3.C. of or* (haft >M.6..? M.3.C. of or* (haft >F.6..? 1nsp.Report of Main 6ear oH 1nsp.Report of F.F. 6ear oH 1nsp.Report of A'. Dias Test Certifi4ate 3f (urfa4e Finish Test Certifi4ate 3f !TFE Mat. For Tai 3ver Die G (trip at Fee'er Test Certifi4ate 3f y'. 6ear !u*p 3!#00#-C!(T Test Certifi4ate 3f !ressure (9it4h1!(#50-#0 Test Certifi4ate 3f Che4< &ave C0: (%-0# Test Certifi4ate 3f Dire4tiona 3perationa !ressure Reief &ave-D!R 0:($ Test Certifi4ate 3f !iot 3perate' Che4< &ave- C1M 0:A%-,0
%%.#$ %%.#5 %%.#: %%.#7
%%.#
12.0
T.C.N&.) 'AT$
C$#TIFICAT$ '$TAI*S
Date' 020#2,00$ Date' %#2%,2,00# Date' %#2%,2,00# Date' %520#2,00$ Date' %$20$2,00$ Date' %$20$2,00$ Date' ,#20:2,00$ Date' ,0202,00# Date' 020#2,00$ %7'ate' 020#2,00$ Date' 0%20:2,00$ --Date' %:20:2,00$ Date' %:20:2,00$ %,0 'ate' 020,2,00$ 50%0 'ate' 0$20#2,00$ ,00#0%:55, 'ate' %%220# , 7 5 ' at e' # 020 %2, 00 $ ,: 'ate' %2052,00$ ,:75 'ate' %72052,00$ , : 7 'a te ' % 205 2, 00 $ ,%7 'ate' ,,20$2,00$ ,0 'ate' %20%2,00$ # 0 'a te ' 0 20: 2, 00 $ #%## 'ate' %020:2,00$ 55,5 'ate' o#2%,2,00# #$05 'ate' %52%%2,00# Date' %$20:2,00$ Date' %$20:2,00$ Date' %020:2,00$ Date' %$2072,00$ ,, 'ate' %:2072,00$ --
M2s. Cro*pton 6reaves M2s. harat iee )t' M2s. harat iee )t' M2s. Cro*pton 6reaves M2s. Messung (yste* !vt. )t'." M2s Messung (yste*s !vt. )t'." M2s. Messung (yste* !vt. )t'." M2s. 6o'en Engg. Co. M2s. E!E !ro4ess Fiter M2s. (haron Engg. M2s. Cenub 1n'ustries )t'." M2s. 1FM Ee4troni4s M2s. 1FM Ee4troni4s M2.s Ener4on (yste*s !vt. )t'." M2s. Ener4on (yste*s !vt. )t'." M2s. Fit4ast Foun'ers M2s. Metaab Enterprise M2s. Mahen'ra =gine M2 s. Me ta a b E nt er pr is e M2s. Metaab Enterprise M2s. Metaab Enterprise M2s . Meta ab Enterpr ise M2s. Metaab Enterprise M2s. Metaab Enterprise M2s . Meta ab Enterpr ise M2s. Metaab Enterprise M2s. Metaab Enterprise M2s. Metaab Enterprise M2s. Ca'*a4h Ma4hinery M2s. Ca'*a4h Ma4hinery M2s. Ca'*a4h Ma4hinery M2s. Ca'*a4h Ma4hinery M2s. C1E!T - Ah*e'aba' M2s Dyna*ati4 Te4hn.)t'.
Date' 0#20:2,00$
M2s !oyhy'ron !vt.)t'.
Date' ,,20:2,00$
M2s !oyhy'ron !vt.)t'.
Date' #020:2,00$
M2s !oyhy'ron !vt.)t'.
Date' %520:2,00$
M2s !oyhy'ron !vt.)t'.
Sur5'%e Are' 5 #9e $ru%# %"#'%# $'r#s.
Sr. N.
N'!e 5 #9e $'r# Pru%# %"#'%# sur5'%e 're' " sq. %! $e%e
1
Bopper
3*,
T#'; qu'"##? use " #9e !'%9"e
2
T#'; $ru%# %"#'%# sur5'%e 're' " sq. %! &1#&
2
;8tension for , 2 1& %opper 3 7lap for Eo control &3 2 12& 4 ellos portion && 2 132 # nlet Eane at bol 2#& 2 #12 & ol /& 2 1/2 * 7eeder frame #&1 2 1122 , -addle (7irst) ,4 2 1&, / -addle (Second) 11/ 2 23, 1 'urret (0ie table 1/&4 1 1/&4 only) 11 'ablet c%ute (nner) 44, 2 ,/& 12 'ablet c%ute *1/ 2 143, (Outer) TOTAL FOR 13104 MACINE N.B. T9e ##'; $ru%# %"#'%# sur5'%e 're' 5 #9e $'r#s 5 CP+6II63 s#'#" !'%9"e #9 B D L'?er '##'%9!e"# s 13104 sq. %!.
13.0
Bre5 Pr%ess +es%r$#".
13.1 $ono layer Operation 13.1.1 7orce 7eedin '%e formulated poder in t%e %opper is pulled don usin a 7orce 7eedin arranement consistin of rotary force feeders. '%e advantae of force feeder is9 ensured die "llin. 13.1.2 Compression '%e loer punc%es9 %ic% alays remain in t%e die9 %old t%e poder t%at is fed into t%e die9 onto it. 7urt%er9 due to t%e rotation of t%e turret9 t%ese punc%es move on t%e do?er assembly %ere only re!uired !uantity of t%e poder is %eld bac6 and t%e rest is scrapped out. -unc%es t%en lide on to pressure roll. +t t%is stae t%e upper punc% moves don t%e pper cam trac6 D oerin9 and t%en t%e pressure roll. ot% t%e punc%es et
pressuri?ed under t%e pressure rolls. +t t%is instant9 due to t%e %eavy compression force t%e tablet is formed. '%e e8cessive bac6pressure enerated in t%is process is absorbed by t%e %ydraulic cylinder9 %ic% is suspended onto t%e loer pressure roll carrier. +fter t%e tablet is formed inside t%e die9 it needs to be ejected out. '%e loer punc% moves furt%er on to t%e ejection cam trac6 and t%e tablet ets ejected out. +t t%is stae9 t%e upper punc% moves onto t%e pper cam trac6 D iftin and lides idly on t%e upper cam piece. +fter t%e tablet is ejected out9 t%e loer punc% moves in t%e loer cam trac6 and comes beneat% t%e feeder and t%e cycle continues. n one revolution9 t%ere is double ejection of tablets. T'@;e# u#$u# - re7;u#" N. 5 s#'#"s * 2
13.2 i ayer Operation 13.2.1 7orce 7eedin n case of ilayer operation9 to %oppers on t%e eit%er sides ould contain to diFerent ranules. '%e ranules for t%e "rst layer are fed in usin ri%t %and feeder %ile for t%e second layer9 usin t%e left %and feeder. 13.2.2 Compression '%e ranules for t%e "rst layer are fed into t%e dies by t%e ri%t %and force feederJ t%e ei%t5adjustin cam reulates t%e correct amount. ;8cess ranules are ejected from t%e die cavity and rejected t%rou% t%e e8cess poer rejection slot. '%e material t%en passes beteen t%e front pressure rolls %ere t%e ranules are tamped by t%e upper and loer punc%es. '%e deree of pressure applied s%ould be just sucient to produce a s%arp demarcation beteen layers it%out aFectin t%e bondin of t%e "rst and second layers. +djustin t%e loer roll by t%e tablet t%ic6ness control can reulate t%e deree of tampin. '%e li%tly compressed tablet9 maintained at a %ei%t "8ed by t%e amount of top punc% penetration at t%e "rst compression station9 passes under t%e second feeder and receives its second c%are of ranules. +ain t%e appropriate ei%t5adjustin cam controls t%e "ll of ranules and t%e surplus ranules are ejected from t%e die cavity and rejected t%rou% t%e e8cess poer rejection slot. ut9 it s%ould be noted t%at t%e ma8imum
dept% of "ll is controlled by t%e amount of t%e upper punc% entry at t%e "rst compression. '%e dies9 containin t%e to layers of material pass beteen t%e "nal compression rolls9 %ic% are adjusted to ive t%e re!uired "nal tablet %ardness. '%e compressed tablet is ejected and deEected don t%e ta6e5oF c%ute (R.B.)
13.2.2 Samplin '%e ei%t of t%e layers can be c%ec6ed %ilst t%e mac%ine is in operation. 'o aFect t%is t%e loer pressure roll of t%e "rst compression station is mounted on an eccentric pin9 %ic% %as a ear cut on one end. '%is ear mes%es it% a rac6 mounted on t%e end of an air cylinder piston rod. %en a ei%t c%ec6 of t%e "rst layer is re!uired t%e selector sitc% is put in HOGI condition. '%is actuates t%e air cylinder9 %ic% in turn pus%es t%e rac6 upards9 and t%us rotates t%e eccentric pin. '%e movement of t%e eccentric pin lifts t%e loer pressure roll and increases t%e %ardness of t%e "rst layer. 0ue to t%is increased %ardness no bondin beteen layers ill ta6e place durin t%e "nal compression and t%e to layers ill separate on ejection. ei%t of t%e "rst layer can be obtained by direct ei%in t%e "rst layer sample and t%e ei%t of t%e second by subtraction t%e "rst layer sample tablet ei%t from t%e total ei%t of t%e completed to5layered tablet.
14.0
S'5e#? 6 I"#er;%
0ue to any of t%e folloin interloc6in reasons t%e mc ill not start or ill stop immediately9 if in operation. '%e mc %ealt%y messaes ill be displayed in reen colour %ile t%e interruption messaes are displayed in red colour. S.N. I"#erru$#7eMess'3e 1 'urret motor overload
2 3 4 # & * , /
1
11
A%#(" a) $ac%ine stops immediately.
C'use a) 'o c%ec6 for resp. output in t%e-C b) 'o c%ec6 t%e ti%tness of t%e timin belt c) 'o c%ec6 for any one p%ase failure. .B. feeder motor overload a) $otor stops $aterial cloin beteen t%e paddles. b) ndication on $$ R.B. feeder motor overload a) $otor stops $aterial cloin beteen t%e paddles. b) ndication on $$ ;merency pus% button $( c doesnot start ;merency pus% button operated bein pressed. $( c uardsopen $( c ill not start and ill $( c set in interloc6 mode. stop if in motion. Bydraulicmotor overload ndication on t%e$$ -%ase7ailure. ubrication oil level lo ndication on t%e$$ ubrication oil reservoir runnin s%ort of oil. atc% si?ecompleted $( c ill not start atc% si?e bein completed and needs resettin. R.B. -oder level islo $( c ill not start. f in a) Bopper runnin out of motion9 it ill stop after fe poder. revolutions. b) Sensor disturbed D Geeds re5settin. .B. -oder level islo $( c ill not start. f in a) Bopper runnin out of motion9 it ill stop after fe poder. revolutions. b) Sensor disturbed D Geeds re5settin. $ac%ine selected in manual $( c ill not run in t is used to "ll up t%e mode continuousoperation. feeders by join.
'%e folloin are t%e alarm functions. '%e alarm messaes ill be displayed in red colour9 and mac%ine s%ould not be run loner.
S.N. A;'r!Mess'3e A%#(" C'use 1 :uards selected in 4y5-ass $ac%ines runs but it% red5 Got applicable mode indication in t%e$$ 2 'ablet countinpro8y not in 1) $ac%ines runs9 but it% Settin bein disturbed. position red5indication in t%e$$ 2) Go tablet countin. 3 $ain set pressure (7ront = $ac%ine runs it% e8cessive 1) Suspected for %ydraulic Rear) overload vibration at loer roll carrier oil lea6ae. 2) Bydraulic pressure not bein set before startint%e mac%ine.
1/.0
L' %';@r'#" %9'r#
-unc% force depends upon tablet si?e9 s%ape9 product c%aracteristics and re!uirement of tablet %ardness. '%e load on punc%es beteen to main compression rolls is developed by a %ydraulic system. t s%ould be set it% t%e %ydraulic system as re!uired. '%e load on punc%es ill be displayed on t%e diital force indicator in NG. Load on punches between two main press rolls in Tons
Digital force Pressure gauge indicator reading in reading in kg/sq. cm kN
1
10
5.6
2
20
11.1
3
30
16.7
4
40
22.2
5
50
27.8
6
60
33.9
6.5
65
36.2
7
70
39
8
80
44.5
9
90
50
10
100
55 6
1.0
Lu@r%'#" requre!e"#s
Sr. N(.
1
2
Sr. N(.
&
3
4
#
*
,
/
+es%r$#("
L(%'#("
+ur'#("
Lu@r%'"# Bindustan S%ell ma6e -etroleumma6e
Reservoir for Resides main 7ill asre!uired ;n6lo5 &, OmalaD 22 continuous inter drive earbo8 mittent it%in loer lubrication cabinet. system. $ain drive it%in loer +bout 2 ;n6lo 5 &, OmalaD 22 +es%r$#(" L(%'#(" +ur'#(" Lu@r%'"# earbo8. cabinet. or6in%rs. Bindustan S%ell ma6e :ear bo8for force it%in turret +bout 2 ;n6lo 5 &, OmalaD 22 Oil nipples for feeder drive ?one or6in%rs. a. 'ablet +djacent upper +pply it% one ;n6lo D &, OmalaD 22 t%ic6nesscontrol roll carrier s%ot it% oil Oil drip cups On uppeu r 7ill aily sre!uired ;n6lo5 &, OmalaD 22 n da loe rint top cam 9 b. :uidebloc6s On cabine +pply it% one ;n6lo D &, OmalaD 22 on turre t ua rd. for bottomlin6. it%in upper s%ot it% oil Oil drip trays ca esides loeu r 7ill aily sre!uired ;n6lo5 &, OmalaD 22 binet n da c. -ivot pin at pper roll +pply one s%ot ;n6lo D &, OmalaD 22 upper roll carrier. carrier trunion it% oil un daily :rease nipples for a. earin
pper and oer +pply one s%ot Servo emD 3 roll centres it% rease un once in a mont% b. earin $ain drive earbo8 +pply one s%ot Servo em5 3 it% rease un once in a mont% $otor bearin a. $ain drive ear +pply manually Servo emD 3 motor after about 3 b. 7orce feeder or6in %ours. drive motor c. Bydraulic pump motor -oer pac6 system esides bottomle 7ill as re!uired ;n6lo D 32 oil reservoir (rear .B.) it%in loer cabinet
+lvania R+ rease
+lvania R+ rease
+lvania R+ rease
'ellus 5 3*
1. 0 FAT PROCE+URE
7actory +cceptance 'est -rocedure s%all be as follosA +fter t%e completion of erection or6 of t%e mac%ine9 client s%all be informed to perform t%e factory acceptance test (7+') Client s%all perform t%e 7+' at t%e manufacturer site and record all t%e data in t%e prescribed 7+' document as per t%e details iven beloA 1. 'est Criteria 2. 0esin veri"cation c%ec6 list
3. 0e"ciency and corrective action report 4. -re D installation re!uirements #. 7inal reports.
1.0
C9'"e C"#r; Pr%eure
C%ane in t%e areed desin s%all be addressed t%rou% t%e ell5de"ned c%ane control procedure.
1.0
,UALIFICATION +OCUMENT REPORT APPROVAL
1/.1 SummaryA
1/.2 Certi"cationsA
20.0
APPEN+I
2.1 ist of +bbreviations. 1 2 3 4 # & * , / 1 11 12 13 14 1#
c:$c:;7+' RS -C SS +C BBRC - R-$ mm NG < B?
Current :ood $anufacturin -ractices. Current :ood ;nineerin -ractices 7actory +cceptance 'est ser Re!uirement Speci"cation -rorammable oic Controller Stainless Steel +lternatin Current Borse -oer Roc6ell Bardness -%osp%orus ron?e Revolution -er $inute $illimeter Nilo Geton
1& 1* 1, 1/ 2 21 22 23 24 2# 2& 2* 2, 2/
+mps $S 0C m+ C 7 Gm N OBGS S!.cm G.. NS!.cm $c °
°
+mperes $icro Sitc% 0irect Current $illi +mpere atts 0eree Centirade 0eree 7a%ren%eit Geton5$eter Nilo atts Oil Bardened Gon S%rin6ae S!uare centimeter Gota enni Niloramper s!uare centimeter $ac%ine.
2.2 Reference documents 2.2.1 $anufacturers roc%ure(s) $anual(s) 'o be supplied it% t%e installation !uali"cation documents. a) b) c) d)
nstruction and $aintenance $anual. $OC Certi"cates 'est Reports nspection Reports
2.3 +nne8ure list Sr.
+es%r$#"
A""e*ure Nu!@er
N. 1
2 3 4 # &
;!uipment roc%ure -urc%ase Order RS Scope of supply 7+' Report nspection Report
0>+GQ1 0>+GQ2 0>+GQ3 0>+GQ4 0>+GQ# 0>+GQ&
2.4 0rain list S.N.
+es%r$#"
1
:.+. 0rain for C-0553* station it% -C system Continuous and ntermittent lubrication
2
+r'" Nu!@er 0>+GQ*
0>+GQ,
