Training Reports GIT at IET

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NATIONAL DIPLOMA IN ENGINEERING SCIENCES
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).
GENERAL INDUSTRIAL TRAINING REPORT
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
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
AIR HANDLING
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
ELASTOMERIC TECHNOLOGIES PVT (LTD)
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.
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
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 identifying and 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 better ways. 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.
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 area because 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.
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 as Yogurt, Cheese, Souse, Bear and Milk Temperature 90C). Also the gaskets of 70840 & 70817 materials of EPDM are used to food applications.
COMPOUND RECIEVED
INSPECTION
EXTRUDING (EXTRUDER) INSPECTION CUT TO SPECIFIED LENGTH
MOULDING (PRESS)
INPROCESS INSPECTION
POST CURING
BUNDELING
DISPATCH
LABELLING
PACKAGING & FINAL INSPECTION

PROCESS FLOW CHART
SAMPLE INSPECTION
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.
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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 Chemical plasticizer Filler Softeners Antidegradant Vulcanizing system
Function in rubber To increase level of plasticity To increase strength, Hardness and reduce cost To aid filler incorporation into rubber To increase service life of rubber product 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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Internal Mixer
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.
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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 chilled water 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 sensors 3. 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 tachometer or 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).
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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 Speed : 75kw : Max 1150 rpm
Power Source : 3 Phase, 415V / 50Hz 2. Gear Box Transmission Reducing ratio Input Speed Lubricating method Coupling method 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. : Double reduction type : 1 / 19.2 : Max 1150 rpm : By trochoid pump : By gear Coupling
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 these potentiometers 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.
The schematic of valve with 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
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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 4 inlet/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 and pressure port blocked.
solenoid operated 4 - way 2 position valve
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A special valve called pre-fill valve is used here, because the main cylinder is much larger one usually larger than 500mm diameter. So to fill that cylinder much high flow rate of oil is needed. So the method use here is two help cylinders are used to raise the platen up, when the platen is going up there is a vacuum is created on the main cylinder. The filling line of main cylinder directly connected to the oil tank through pre-fill valve. This valve is operated by a pilot line. When the help cylinders raising the platen the pre-fill valve is opened by the pilot line and allow to fill the main cylinder freely. After the platen reached to the high pressure limit switch , pilot oil line is cutoff and pre-fill valve is closed. Then the high pressure oil line which is connected to the main cylinder through pre-fill valve is activated and apply maximum clamping force to the press.
PREFILL VALVE
Pre-fill valves operate similarly to pilot-operated check valves, but they are usually much larger. Some pre-fill valves can handle flows in excess of 6000 gpm at pressure drops of less than 4 to 8 psi. Their normal function is to fill and exhaust a large bore cylinder as it travels to and from contact with the work piece. Large, high-tonnage presses -- both vertical and horizontal -- use pre-fill valves to reduce pump size while maintaining cycle time. To pressurized the hydraulic fluid a double vane pump is use in an every press. Because for raise the platen up using help cylinders a low power is needed. So low pressure pump can handle the work. But to get maximum clamping force we have to pressurize the main cylinders and So we need much more pressure. Hence double vane pump is used energy saving.
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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 rotor that 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.
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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 supplied to 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 to produce 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 the force 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) 2. Inlet side header 3. Outlet side header 4. Steam trps - To control the tempreature - A temporary storage of incoming steam - A temporary storage of steam - To separate water from steam
HEADER
STEAM TRAP
TO HOTWELL
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HEDER
STEAM FROM HEADER
PRV
PLATEN
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 pilot diaphragm, 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 TRAPS The 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 tracing applications. 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 to allow 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 are curried using Nitrogen and some are curried by using a mix of both. When considering the technical details of an oven, Temperature range Power Electrical supply Heating : 25 - 200 OC (Not less than ambient) : 80kw : 400V / 3 phase : 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 is mounted 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 , Stype, B - type and C - type.
1.5.2 SCR (Power Regulator)

A silicon-controlled rectifier (or semiconductor-controlled rectifier) is a four-layer solid state current controlling device. The name "silicon controlled rectifier" or SCR is General Electric's trade name for a type of thyristor. 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.
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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 Working Temperature Max supply pressure Delivery pressure (N2) Capacity : 400V / 50Hz / 100A : +5oC - 40oC : 10 bar : 8 bar : 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

CUSTOMER INQUARY
FILE
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)
MACHINING (CNC - MACHINE)
GRINDING (CYLINDRICAL GRINDER)
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 Control Number of Axes X Axis Travel Y Axis Travel Z Axis Travel Tool Stations Spindles Motor Power Spindle Speed
: VERTICAL : Fanuc :3 : 2060 mm : 800 mm : 660 mm : 20 :1 : 25 kw : 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 G01 G02 G03 G21 G28 G41 G49 G80 G81 G83 G86 G90 G91 G92 G98 - Rapid Traverse - Linear Interpolation (Cutting Feed) - Circular Interpolation (Clockwise) - Circular Interpolation (Counterclockwise) - Input in mm - Return to reference point - Cutter compensation left - Tool length compensation cancel - Canned cycle cancel - Drilling - Peck drilling cycle - Boring cycle - Absolute command - Incremental command - Programming of absolute zero point - Return of initial point
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Commonly used M - Codes are, M03 M01 M05 M09 M30 M98 M99 - Spindle Forward - Option Stop - Spindle stop - Coolant off - Program end - Subprogram call - 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 G28 G90 G92 S1200 M03 F300 G00 M98 G91 M05 M09 G91 G28 G28 M01 M30 Z0.0 Y0.0 Z200.0 P100 Z100 ; Feed rate X0.0 Y0.0 Z0.0 Z0.0 X0.0 Y0.0
; Spindle speed
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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, copper slag, walnut shells, powdered abrasives, even bits of coconut 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. For etching 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 of anything that may be clinging to it. The second is to either etch or carve designs or words into glass or a similar material
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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.
1.7.1 SEQUENCE 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 solenoid valve 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 electric cell 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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1.7.2 WEEKLY 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.
1.7.3 MAINTENANCE 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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STATE PHARMACEUTICALS MANUFACTURING CORPORATION
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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 a gift 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 nonpenicillin 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 for pharmaceuticals 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 of Health. 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 Working director General Mamager
Production Manager
Maintenance Manager
Asst. Manager (Sales Promotions)
Planning and Procurement Manager
Formulation and developmen t Manager
Quality control Manager Asst.Quality control Manager
Management Accountant
Asst. Engineer (Electrical) Engineering Asst.(elec) Senior Maint. Tech.(elec) Maint. Tech. (elec)
Asst. Engineer (Mechanical) Engineering Asst.(mech) Senior Maint. Tech.(mech) Maint. Tech. (mech) Driver / Porter
Administration Officer
Receptionist Typist General clark Pharmaceutical technologist (Plannig)
Asst. Formulation and development Manager
Asst. Chemist
Quality control Officer
Technical Asst. Quality control Asst.
Planning Assistants Stores Assistants Accountant
Asst. Production Manager Pharmaceutica l Technologist Senior process Asst. Process Assistants
Laborers
Accounts Asst.
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2.1.3 SPMC Product List

Aluminium Hy.Tab. BP 500mg Amoxicillin Cap. BP 250mg Amoxicillin Cap. BP 500mg Ascorbic Acid Tab. BP 100mg Benzhexol Tab. BP 2mg Carbamazepine Tab. BP 200mg Chloroquine Phos. Tab. BP 250mg Cloxacillin Cap. BP 250mg Cloxacillin Cap. BP 500mg Diclofenac Sodium Tab.USP 50mg Erythromycin Stearate Tab. BP 250mg Frusemide Tab. BP 40mg Indometacin Cap. BP 25mg Mebendazole Tab. USP 500mg Sachet Metformin Tab. BP 500mg Paracetamol Tab. BP 500mg Phenoxy.penicillin Tab. BP 125mg Prednisolone Tab. BP 5mg Propranolol Tab. BP 40mg Salbutamol Tab. BP 2mg Salbutamol Tab. BP 4mg Theophylline E. R. Tab. 300mg Verapamil Tab. BP 40mg Vitamin B Compound Strong Tab. BPC Amoxicillin Tab. USP 125mg Amoxicillin Cap. BP 250mg. - Bliter Amoxicillin Cap. BP 500mg. - Blister Atenolol Tab. BP 50 mg (Blister) Bisacodyl Tab. BP 5mg Chloramphenicol Cap. BP 250mg Cimetidine Tab. BP 200mg Cloxacillin Cap. BP 500mg. - Blister Co-Trimoxazole Tab. BP 480mg Diethylcarbamazine Tab. BP 50mg Folic Acid Tab. BP 5mg Famotidine Tab. USP 20mg ( Blister ) Mebendazole Tab. USP 500mg Mebendazole Tab. USP 100mg Paracetamol Tab. BP 500mg. (Blister) Paracetamol Tab. BP 500mg Phenoxy.penicillin Tab. BP 250mg Prednisolone Tab. BP 5mg Rifampicin Cap. BP 150mg Salbutamol Tab. BP 2mg Theophylline E.R. Tab. 125mg Trifluoperazine Tab. BP 5mg Vitamin B Complex Tablets
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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 of air (primarily temperature and humidity) to more favorable conditions. More generally, air conditioning can refer to any form of technological cooling, heating, ventilation, or disinfection 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.
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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 coils can 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 are packaged 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, cooling tower, 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 the air 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 reheated 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 Output Compressor Running Current Refrigerant Design pressure : 3 - phase, 400V, 50Hz : 2 30 kw : 111A : R22 2 15 kg : 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 small displacement 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 or change 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 Difference between discharge pressure of right and left compressors Suction pressure of refrigerant Difference between suction pressure of right and left compressors Cooling water in flow rate Chilled water in flow rate Cooling water outlet temperature Cooling water inlet temperature Chilled water outlet temperature Chilled water inlet temperature : 15 - 18 kg/cm2 : Under 1 kg/cm2
: Within 3.5 - 6 kg/cm2 : Under 0.5 kg/cm2
: 664 l/min : 520 l/min : 30OC - 40OC : 25OC - 35OC : 5OC - 12OC : 10OC - 152OC
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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 including drinking.
MUNICIPAL WATER
UNDERGROUND SUMP
SAND FILTER
FILTERED WATER TANK
DEIONIZER
WATER SOFTNER
CARBON FILTER
ELEVATED WATER TANK
ULTRA- VIOLET STERITRON
NONPHARMACEUTICAL WATER
PHARMACEUTICAL WATER
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.
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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 MIXED BED 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 as calcium, 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. This characteristic 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 of the 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 where the two meet. After settling, acid is injected up flow from the bottom and caustic soda is injected down from the top. The two chemicals meet at the resin interface. When all the chemicals have been added, they are slowly high concentration is removed. When rinsing is complete, air is injected in to the tank, thoroughly mixing the two regenerated resins into one homogeneous bed. The mixed bed deionizer will produce high quality deionized water when operated on either hard or soft water that meets the specifications below. LOADING THE RESIN. The cation resin will be loaded first. The resin volume must be adjusted to a specified point below the mid manifold. - At this point, the tank is empty and has been tested for leaks. Refill the tank with soft water. - Add about 75 85 % of the cation resin (Cullex) being careful to keep it off the upper laterals.
- Boost the resin bed up briefly until its top reaches the top of the lower observation window and let the resin bed settle. This treatment is somewhat equivalent to a backwash.
- Let the water flow as fast as it will, until it reaches the top of the upper window. Stop the flow and allow the resin to settle. After it has settled, drain the tank. Let the water drain from the tank until it is about 3 inches above the resin. Stop the draining. - Note the location of the resin bed surface. The correct location is 1 to 2 ( 2.5 5.1 cm) below the center line of the mid manifold laterals.
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- Replace the top head and air vent connection. - The excess fine particles in the cation resin must now be washed out. This will require a much higher than normal flow rate. Allow the resin bed to rise until it can be seen in the upper observation port. Continue this fines removal process for 30 minutes or until no more fines are observed at the drain, then stop the flow. - After the resin bed has settled, resume normal back wash. Allow the resin bed to settle. - It is critically important that the cation resin never be above the mid-manifold laterals. - With the cation resin level correctly adjusted, the anion resin may now be loaded. Allow the tank to refill up flow. When the water level has reached 6 inches below the upper observation window, stop filling. - Remove the top head and air vent connection. Add all the anion resin. - Fill the tank with soft water by using a pail or garden horse. Replace the top head and vent connections.
Types of Resins Cation : Type Regenerant chemical CH 1, strong acid type ( cullex ) 200C Be. Hydrochloric acid, Tech. grade
Anion : Type, Strong Base Regenerant chemical CS 2, Strong base, Type ll Sodium Hydroxide, rayon or mercury cell grade, either flake, pellets, or 50% liquid.
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ULTRA- VIOLET STERITRON UNIT
The UV- steritron is a wall mount type. The sterilizing effect of DI water may obtain from this instrument. Inside the sterilizer container, there are 02 germicidal lamps. The ultra-violet rays (253.7nm) coming from the germicidal lamp has a powerful sterilizing effect. These rays are very strong for human eyes. Each germicidal lamp has a service life of about 3000 hours. When total numbers of operating hours exceed ultra-violet permeability of lamps get decreased. Then should replace lamps. NEUTRALIZATION TANK Waste water from re-generation of the De-ionizr unit is alkaline in pH. It is temporarily stored in the neutralization tank, where it is neutralized by HCl acid injected by a chemical feeder and then discharged.
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2.2.3 EFFLUENT TREATMENT PLANT (Waste Water Treatment Plant )

The purpose of this equipment is to purify the waste water drained from the pharmaceutical center and to prevent the contamination of environment. The waste water discharge from a factory should be treated before disposal in order to protect the environment. If the waste water is not treated, the decomposition of organic materials it contains can lead to the production of various malodorous gases. Waste water contains numerous diseases causing microorganism and toxic compounds. Because of these reasons, waste water discharge from a factory should be treated well.
Classification of treatment methods

1. Physical Treatments Eg : Screening, mixing, sedimentation. 2. Chemical Treatments Eg : Precipitation, disinfection. 3. Biological Treatments 1. Suspended growth process Eg: Activated sludge process, aerated lagoons. 2. Attach growth process. Eg: Trickling filters, rotating biological contractors (RBC), packed bed reactors.
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Influent Sewage water
Pumping station (bar screens 20mm &50mm)
Fine screen (0.5 mm)
Equalization tank (air diffusers)
Aeration tanks 1/2
Removed by MC Sludge Storage tank
Primary settling sludge Sludge Settling tank
To the bolgoda lake
Effluent treated water Chlorinator
Sedimentation (liquid)
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BASIC BLOCK DIAGRAM OF WASTE WATER TREATMENT PLNT
Machine room. This consists of aeration device (four aeration blowers), exhaust fan and control panel of the plant. The purpose of the aeration device is to blow the air into the sludge storage tank, equalization tank and aeration tank. Pumping station In this device, the sewage influent mixed with process waste water is done. This tank is constructed below the ground level and there are two bar screens (bar screen 150mm, bar screen 2-20mm). Bar screen consists of inclined parallel bars and this device removes large particles in waste water. In waste water treatment process, bar screens are used to protect pumps, valves and pipe lines from damage or clogging by large objects. There are two submersible pumps (screen pumps), which transfer waste water to the equalization tank through a fine screen. Fine Screen This is installed to remove the impurities that are not eliminated by bar screen. (impurities may not flow to equalization tank.) The fine screen is a perforated plate with 0.5mm opening. The impurities remove by fine screen will be discarded to the basket placed under fine screen. Therefore waste water will flow in to equalization tank. The collected solid material in the basket is replaced once a week.
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The Automatic washer is installed to supply water to the automatic spray nozzle and it helps to remove solid matters which attached to fine screen.
Equalization tank The capacity of this tank is 49 m3 having o2 sets of waste transfer pumps, raw water measuring notch box and diffuser. Air must be taken into the diffuser for 24hrs. Waste water transferred is stored in this is stored in this tank before it is being sent to aeration tank. The characteristics of the waste vary in a day also the discharge rate is not uniform or continuous. Therefore the waste may require equalization before it is subjected to the treatment. The waste water in this equalization tank should be mixed by supplying air through six diffuser cylinders, placed at the bottom of the tank. One aeration blower supplies air to the diffuser cylinders. Aeration Tank 1 & 2 There are two aeration tanks. Waste water from equalization tank is transferred to the first aeration tank by waste transfer pump via a measure notch. Then it is transferred to the second aeration tank by gravity flow. Fourteen diffuser cylinders, 8 in the first tank and 6 in the second tank are used to aerate these tanks. Air to these diffusers is blown from aeration blowers in order to achieve the aerobic environment. Sedimentation tank The capacity of this tank is 15 m3. This is used to separate the bio-mass from the water produced in aeration. Rectangular sedimentation tank contains a conical bottom and air lift pump is used to remove sludge deposited in the bottom of the tank Parts of the transferring sludge are sent to 1st aeration tank to maintain the required bacteria growth. The clarified liquid is transferred to form breaking pump tank by using the gravity flow. Conical bottom surface is designed to improve efficiency of sedimentation operation. Foam breaking pump tank The capacity of this tank is 1.2m3. A submersible pump in this tank is used to transfer the clarified liquid in to five spray nozzles in the aeration tanks in order to eliminate the foam generated in the aeration tanks. Waste water normally contains soap, detergents and other surfactants. Because of those chemical matters, foams are produced in the aeration tanks when the waste water is aerated.
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Foaming action produced a forth that contains sludge solids, grease and large number of waste water bacteria. It will contaminate whatever it touches. Besides being unsightly the forth is a hazard because it is very slippery. Also when it has dried, it is difficult to clean off. To control the forth formation, normally a series of spray nozzles are mounted along the top edge of the aeration tank opposite the air diffusers. Sterilization Tank The purpose of this device is to sterilize the bacteria in the supernatant liquid of the sedimentation tank by chlorine and to discharge it. This device is composed of the sterilization tank and chlorinator. (The concentration of residual chlorine shall be 0.4ppm) Sludge storage tank The purpose of this tank to temporarily store the sludge separated by the sedimentation tank and transferred by the air lift pump. This device is composed of sludge storage tank with the capacity of 17m3 and sludge transfer pump.
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2.2.4 BOILER AREA

There are 2 horizontally mounted, single pass, Diesel fired, fire tube boilers are used to produce steam for chiller heating coils and production zone. Those are usually runs at 2.5 - 3 bars of pressure. so the safety valve is adjusted to 5.5 bars of pressure. Those are packaged type fire tube boilers in which a Morrison furnace is fitted so as to form a complete water- cooled wall inside the combustion chamber and to realize the maximum efficiency of heat transfer and a uniform thermal absorption is made all over the radiant surface by reverse firing. The flame of burner formed up around the axis direction of furnace will complete its combustion before it reaches the rear part of the furnace. The combustion gas which started from the furnace rear part, enter into the front smoke box, passing through special tubes, proceed to rear smoke box, and reach the exhaust port. Due to high thermal conductivity resulting from special tubes used for fire tubes, fewer number of fire tubes compared with conventional fire- tube boilers are sufficient and will obtain superior results to similar boiler. Boiler Specifications Capacity Max. Working pressure Heating surface Consumption of fuel : 1.2 Tons/hr : 10 kg/ : 14.1 : 73 kg/h
Front Smoke Box This is the room where the combustion gas returning from the combustion chamber furnace is contacted with special tubes and it is inwardly covered with refractory materials. It is outwardly double in structure to be cooled by the combustion air which is sucked in by a forced draft fan. The surface temperature inside the smoke box is low and the air, on the other hand, when heated to a considerable high temperature, will serve to raise the efficiency of combustion. The fire box is provided with double- structural doors (right / left) which are prepared for the time of replacing smoke tubes. The interior of smoke- box is all covered with refractory materials and divided into several blocks, each having a handle, which are convenient for operation. (Inside of the smoke- box is formed with fire- brick walls)
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Rear Smoke Box This is a chamber where the combustion gas which passed through these special tubes will be guided to the flue or to the chimney and it is covered inside with refractory materials. A damper is equipped in the upper part of the rear smoke box. The damper has a damper latch switch which makes and oil the main oil valve open only when the damper is fully opened. The door for brushing the smoke tube is fitted with hinges so that it can be opened with case. The rear end plate has Oxygen peeping holes to watch the flame when requiring the combustion control.
CONTROL OF THE BOILER
A motor driven timer unit takes the total timing and control part. All inputs and outputs were set to that unit, it will energize proper output path according to its timing, and other conditions (inputs) are met. The timer will start when we pressed the start button of the boiler. Automatic control device The function of this device is to maintain the steam pressure of the boiler outlet at all times constant to the variation of the load and give the good quality steam continuously, and to carryout combustion control suitable for the load to reduce the fuel consumption (cost saving). Automatic starting / stopping device : (to start / stop the combustion device according to the load) High low control device : (for automatic combustion to control combustion depending on the steam pressure) Safety device : To shutoff combustion in an emergency or in an abnormal case.
Automatic combustion High- Low controller In order to maintain the steam- pressure within the constant range in response to the variation of load, this device detects the steam pressure and automatically adjusts the combustion by the high- low controller within upper and lower limits. Safety device In order to ensure safety control of operation of the boiler, following safety devices are provided, which automatically stop combustion and simultaneously release alarm in case. Flame safety device (Abnormal flame breaking device)
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Combustible gas discharge device (Pre-purge: for ventilation in furnace / Post purge: for air purge in furnace) Pre-purge effected : 55 sec Post-purge effected : 20 sec Interlock circuits: Solenoid valves / switches Low combustion interlock of the Forced Draft Fan Stoppage of electric supply Oil solenoid valves
Operating Procedures There are two methods: 1- Automatic 2- Test The combustion device automatically starts operation, which is controlled in respond to the steam pressure reaches the upper limit of the set- pressure, if automatically stops. Sequence of automatic combustion control of boiler 01- Starting (operation) (In this moment, The boiler water level should be higher than low water level Steam pressure should lower than the lower limit pressure for operation) 02- Pre-purge (55 sec) 03- Confirmation of low- fire position (by interlocks) 04- Ignition spark 05- Low combustion (No.1 oil valve open) 06- Flame detection 07- High combustion (No.2 oil valve also open) 08- Stoppage of combustion 09- Post-purge 10- Full stoppage Boiler Burner This boiler consisted with combustor type Pressure Atomizing Burners. Combustor Type means burners with all equipments; Damper motor Solenoid valve Igniter.. etc
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It consisted with 2 nozzles. They are, 1. Low Combustion nozzle 2. High Combustion nozzle At the start the low fire solenoid energized and starts fuel injection in low fire nozzle. At this moment the damper should be in correct position to give the required air flow to burn the fuel. The timer unit controlled it. After that according to the correct timing the low fire solenoid gets energized and starts fuel injection. Then the damper gets its maximum open position to give maximum airflow to the combustion. Burner Structure This burner applies high pressure on fuel oil, which is atomized and sprayed by the nozzle. The atomized fuel oil is ignited directly with an electric arc. Flame Funnel This contains diffusers, nozzles, nozzle adaptor and ignition electrodes inside the and restricts the size of flame. Nozzle Two nozzles are provided. (For low / high combustions) The right nozzle is for low combustion and the left one is for high combustion. Flame detector (Flame eye) This is provided to check the state of combustion in automatic operation. Cadmium Sulfide (CdS) which converts light into electric resistance is used as a sensing element. Ignition fail or unstable combustion is detected by means of this. Ignition system Potential boosted to 10kV by the ignition transformer, mounted on the burner, is led to the electrode through a high voltage cable. The tip and the electric are is formed across the gap to directly ignite fuel oil sprayed out of the nozzle
BOILER WATER TREATMENT
Three types of impurities exist in all supplies and can cause a wide range of problems in boilers. These impurities are suspended solids, dissolved solids, and dissolved gasses. Water picks up the impurities from the ground it contacts and the air through which it falls. The type of impurity depends on contact time, and stream velocity. The amount of rainfall and where the rain occurs on the watershed can and does result in changes in the character of the water throughout the year. Water supplies typically come from one of two sources, ground water or surface water. Generally, ground water contains more dissolved solids and less suspended solids and dissolved
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gases. Generally, surface water contains more suspended solids and dissolved gases and less dissolved solids. Most problems due to impurities present in the water can be solved chemically, one way or another. It is usually most economical, however, to address the impurities by physical or mechanical means, using chemical treatment only to clean up the remaining traces left after physical treatment. Not only will this pre-treatment minimize chemical costs, it also has the difficult to measure benefit of improving a plant's reliability while simplifying operators' jobs. In SPMC boiler water treatment process is consisted with Water softener and Chemical injection pump. In here he softener is use to reduce hardness and chemicals are used to remove dissolved oxygen from the boiler water. NALCO is the brand of chemical they used. Three tests are done daily to measure dissolved Oxygen amount, Sulfite amount and Phosphate amount. And also TDS value and hardness of the softner outlet are measured in three months periodically. Blow down is carried out 2 times per a shift to control TDS value less than 3500 ppm.
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2.2.5 PNEUMATICS
Pneumatic power is used here to operate various types of machine parts in production area. Some of them are, powder conveying machine, Coating machine, Blister packing machine, Product filling and etc.. An every pneumatic system consisted with following main units. 1. Air compressor 2. Air dryer (if required) 3. FLR unit (Filtering, Lubricating and regulating) 4. Control valves 5. Actuators
Fig. 2.5.1 BASIC PNEUMATIC SYSTEM
COMPRESSOR
An air compressor is a device that converts power (usually from an electric motor, a diesel engine or a gasoline engine) into kinetic energy by compressing and pressurizing air, which, on command, can be released in quick bursts. There are numerous methods of air compression, divided into either positive-displacement or negative-displacement types.
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Fig. 2.5.2 TYPES OF COMPRESSORS
In SPMC we can found Oil free screw compressor (ATLAS COPCO). General Specifications: Type Flow rate Compressor Maximum Pressure Main Motor capacity Cooling Fan
: Oil free (Screw type/2stage) : 8 m3/ min. : with cooler unit and water separators : 7.5 bar : 55KW : 2KW (for cooling system)
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Fig. 2.5.3 SCREW COMPRESSOR DESIGN
When considering a screw compressor, screw elements main parts are the male and female rotors, which move towards each other while the volume between them and the housing decreases. Each screw element has a fixed, integrated pressure ratio that is dependent on its length, the pitch of the screw and the form of the discharge port. To attain the best efficiency the pressure ratio must be adapted to the required working pressure. The screw compressor is not equipped with valves and has no mechanical forces that cause unbalance. This means it can work at a high shaft speed and combine a large flow rate with small exterior dimensions. An axial acting force, dependent on the pressure difference between the inlet and outlet, must be taken up by the bearings. In an oil-free compressor, the air is compressed entirely through the action of the screws, without the assistance of an oil seal. They usually have lower maximum discharge pressure capability as a result. However, multi-stage oil-free compressors, where the air is compressed by several sets of screws, can achieve pressures of over 150 psig, and output volume of over 2000 cubic feet (56.634 cubic meters) per minute (measured at 60 C and atmospheric pressure). Oil-free compressors are used in applications where entrained oil carry-over is not acceptable, such as medical research and semiconductor manufacturing. However, this does not preclude the need for filtration as hydrocarbons and other contaminants ingested from the ambient air must also be removed prior to the point-of-use. Subsequently, air treatment identical to that used for an oil-flooded screw compressor is frequently still required to ensure a given quality of compressed air.
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AIR DRYER
A compressed air dryer is a device for removing water vapor from compressed air. Compressed air dryers are commonly found in a wide range of industrial and commercial facilities. The process of air compression concentrates atmospheric contaminants, including water vapor. This raises the dew point of the compressed air relative to free atmospheric air and leads to condensation within pipes as the compressed air cools downstream of the compressor. Excessive water in compressed air, in either the liquid or vapor phase, can cause a variety of operational problems for users of compressed air. These include freezing of outdoor air lines, corrosion in piping and equipment, malfunctioning of pneumatic process control instruments, fouling of processes and products, and more. There are various types of compressed air dryers. Their performance characteristics are typically defined by the dew point. In SPMC the air dryer is consisted with some water absorbing material to remove moisture in compressed air.
AIR RECIEVER
An air receiver is essential to every compressed air system to act as a buffer and a storage medium between the compressor and the consumption system. There are in principal two different air receivers in a compressed air system:
PRIMARY receiver - located near the compressor, after the after-cooler but before filtration and drying equipment
SECONDARY receivers - located close to points of larger intermittent air consumptions
Fig. 2.5.4 AIR RECIEVR INSTALLATION
The maximum capacity of the compressor in a well designed systems always exceed the maximum mean air consumption of the system (maximum mean air consumption is the mean air consumption over some reasonable time).
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Since the maximum capacity of an air compressor also always exceed the minimum air consumption in the system - the compressor must modulate its capacity during normal work, often by using primitive strategies as on/off modulating or more advanced strategies as frequency drives and inverters. Primitive modulating strategies cause more pressure variations in compressed air systems than more advanced strategies. In addition, the air consumption vary due to the process supported. In shorter periods the demand for compressed air may even exceed the maximum capacity of the compressor. In fact, it is common in well designed systems not to design the compressor for the maximum peek loads. Air receivers in compressed air systems serves the important purposes of

equalizing the pressure variation from the start/stop and modulating sequence of the compressor storage of air volume equalizing the variation in consumption and demand from the system
In addition the receiver serve the purpose of
collecting condensate and water in the air after the compressor
FLR- UNIT
Fig. 2.5.5 FLR - UNIT
This unit is used to protect the system from undesirable foreign particles, to maintain a steady pressure of air supply and to ensure a mist of lubricating oil film to the compressed air to protect the system from failure due to friction. To maintain the overall health of the system and other system components, this unit should be properly maintain.
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2.3 Production department
2.3.1. Introduction
The production department mainly consists of General Drug Zone, Penicillin Zone and F Zone. In GD Zone, all non-penicillin tablets and capsules are manufactured. In penicillin zone, all penicillin drugs are produced. Automated packaging line used for packaging of GD products in F zone. Manufacturing facility equipped with the most modern Japanese, Korean and German machines with an annually installed capacity of 900 million units of tablets / capsules. Production zones consist of ultra clean and clean zones. In ultra clean zone, almost sterile air is fed through high efficiency particulate air (HEPA) filters at positive pressure of +1.5mmAq, plate count is less than 20cfu (colony forming units), Humidity is controlled less than 55%. In clean zone also air fed is in filtered with high efficiency particulate air (HEPA) at positive pressure of +1.0mmAq, plate count is less than 30cfu. It is important to note that the two main production areas; GD and Penicillin are completely separated and every step is taken to avoid the cross contamination of two areas. The production area is hygienic design according to GMP requirements in pharmaceutical industry. Before entering to the production zones, general factory uniform is changed to white overall, Arab cap with white shoes which are only in the production area. Necessary goggles, masks and earplugs must be wearing during the production. In penicillin zone, production uniform is blue tagged one and chlorine mats are kept to step on them while coming out the penicillin zone to destroy penicillin coming out. Due to the water sensitiveness of penicillin. Only dry processes are carried out in production. But in GD zone, both dry and wet processes are exists. When entering into the production zone (GD or Penicillin), at first we should remove cell phones, wrist watches and all other ornaments. Then we should go through air shower and clean dust. After that remove our shoes and enter into the shoeless area. Then we should wear the special uniform and clean shoes should wear by entering into the clean shoe floor. After that we should wash our hands by using detergents and enter in to the clean zone through dirty zone.
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2.3.2 Production flow chart for general Drugs
Packaging material storage
Raw material storage
Pretreatments Mixing treatment / Sieving / Atomizing / colouring matter
Weighing
In process goods storage for dispensed powder
Spraying granulation / Drying
Mixing / Oscillating / Dry granulation
Mixing / Wet granulation
Oscillating / Drying / Sieving
Bottle washing / Drying
Mixing
In process goods storage for granulated powder
Tabletting/ Capsule filling
In process goods storage for tablets / capsuals Preparation paste syrup
Sugar/ Film/ Enteric Coating (for necessary products only)
Packaging
Quarantine area / Product storage
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Pre-treatment process Pre-treatment are required only when the raw materials form agglomerates or they are not enough as the required particle size. Sieving Sieving of lactose and maise starch. Those are the materials mainly subjected to sieving pre-treatment. Raw materials are sieve through a specified mesh to ensure that those are in within their standard limits. Sieving machine consist of a vibrating system and pneumatic conveying system. The material is sucked from suction nozzle negative pressure air generated by a venturty system. Since dust and high noise is generated during sieving, planned preventive maintenance must be worn. Milling The milling operation is done to producing smaller particles from solid materials by applying mechanical force. There are two types of mills are used in SPMC. 1- Fine mill for producing fine powder 2- Multi mill to take coarse powder In fine milling, the material to be milled is fed to the hopper and then it carried to the centre of grinding chamber through a screw feeder. The grinding chamber consist hammers and lining plate, which are directly connected with the main shaft. The material entered in the grinding chamber receives centrifugal force by rotating hammers with high speed and fly over the lining plate and receives impact and shearing forces and then milled. The milled product is collected in to a product discharge bag through the perforated screen located at the bottom of the grinding chamber. Fine milling machine has a cooling jacket, which is used to transfer the cooled water for cooling the grinding chamber as it get heated during the milling operation. Here also ear plugs, masks & goggles should be worn. The following factors are mainly used to control the adjustment of the particle size. Shaft rotating speed Screen size Feed rate of materials Clearance between the hammer and lining plate
Drying Drying is done as a pre-treatment mostly in penicillin zone due to only dry processes are carried out in there. They are used hot air drying oven for this purpose. I involved drying of DC lactose in the penicillin zone.
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Weighing This is the initial step in sequential production process. For weighing process, there are several electronic balances with capacities 600kg, 300kg, 60kg & 5kg in order to improve accuracy when weighing different quantities. Materials in the manufacturing formula are weighing according to the double cross checks method. That means one person weigh the amount of material which wants to the manufacturing process & the other person try to maintain correct amount of material which reduce from the main container after the weighing. This process must do accurately because it will effect to the content of ingredient in the tablet or capsule. The purpose of this method, Mixing There are different types of mixtures are used in SPMC. Selection of mixtures depends on type of mixing (whether dry or wet mixing), mixing quantity, mixing time, mixing speed and type of ingredients have to be mixed. For a particular product, type of mixture is decided by formulation department at the stage of formulating the drug. Drum mixer Double cone mixer Planetary mixer Homogeneous mixer Dry mixing of small quantities Dry mixing of large quantities Used for both dry & wet mixing Used for mixing solutions Reduce the human errors Increase the accuracy Reduce the weighing machine errors
Granulation Granulation is very important unit operation in pharmaceutical manufacturing and following properties are achieved in the materials after granulation. 1. Good flow properties 2. Reduce dusting losses 3. Easy to achieve desired product property such as friability and hardness from a certain structure forms 4. Better product appearance 5. Creating of uniform non-aggregating blends There are three varieties in granulation process called wet granulation, dry granulation & spray granulation.
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Oscillating Granulator This is the step used in wet granulation process. After the mixing process, this machine is used for oscillation to get the fine particles for manufacturing process. Oscillator has two rollers, which rotates opposite directions. Coarse particle pass through the rotors and then pass through the screen. Then it becomes fine particles. Machine wastage can occur during the production process when using this machine.
Fluid Bed Drying
This is the equipment used to drying in the wet granulation and the spray granulation processes. In this dryer the hot air is used to dry the materials and it will pass from the bottom to top of the dryer. Steam is used to produce hot air. When the hot air pass through the granules they are lifted and then fall back like boiling liquid, and the moisture inside the granules will be removed totally because of the boiling liquid motion, the contact between the hot air and granules will be increased and each particle will be surrounded by the hot air completely. In this operation, the higher and lower drying temperature can be used but in most process lower temperature is applied to prevent the thermal decomposition by the higher temperature. When the materials are fluidized they can remove through the duct which is used for exhaust the hot air from the dryer. To prevent that filters with the shape of the bags are located at the top. Below the dust collecting filters the sets of pins are provided to neutralize the electrostatic charges. This is very important set up for protect the works from the electric shock.
Tableting
Tableting is done using tableting machines and there are six tableting machines in GD zone and one is in penicillin zone of SPMC. Before starting the tableting process, it should be ensured that there is no tightness or abnormal sound coming out from the machine, by turning the manual handle. It is important to check the oil level, oil pressure and the punches oiling system also. After confirmed those conditions tableting process is started and initially in-process checks for weight variations, thickness and hardness have to be done. Because those properties can be changed with machine setup and can be corrected by varying following things. Weight variation Adjusting filling depth Thickness & Hardness Adjusting main pressure and pre-pressure
Capsule Filling
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Main functions of the machine 1- Capsule feeding, aligning, and inserting into format bores 2- Capsule separation 3- Exposing capsule body 4- Dosing station for pellets, tablets, or coating tablets 5- Dosing station for powder 6- Dosing station for pellet 7- Faulty capsule ejection 8- Aligning capsules 9- Placing capsule caps onto capsule bodies 10- Lose capsules 11- Discharge of correctly filled and closed capsules 12- Cleaning of segments by vaccum Coating This process is done only for specific products. There are three types of coating processes such as; Film coating Enteric film coating Sugar coating
But in SPMC sugar coating is not done in present. Tablet coating is done due various aspects as follows. Mashing of undesirable taste, smell or colour Stabilization of an active ingredient Prevention of dust generation of drugs those are more active or allergic Adjustment of solubility Improvement of appearance and commercial value
The main steps involved in coating process
In-process checks for core tablets
Tablets loading
Preheating
Coating solution spraying
Unloading
In-process checks for coated tablets
Drying
Cooling
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Packaging
Manufactured products are packed in ultra-clean are according to the GMP requirements after approved to release by quality control department.
CERTIFICATION - 01 Name Of Apprentice Registration No Course Field Category of Training Duration of Training : U.D.S SILVA : MG/09/7711
: National Diploma in Engineering Sciences : Mechanical Engineering (General) : GIT (General Industrial Training) : 16/08/2012 - 31/01/2013 Ceylon Petroleum Storage Terminals Ltd Mr. H.A.N. Hettiarachchi
Name of Establishment : In Charge of Training :
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Signature of Trainee
Date
I hereby certify that above information which is regarding the industrial training covered by the trainee is true at the best of my knowledge and this report is self constitution of him.
................................................... Signature of In charge of training
...................................... Date
: National Diploma in Engineering Sciences : Mechanical Engineering (General) : GIT (General Industrial Training) : 26/03/2012 - 31/05/2012 Frigi Engineering Services (pvt) ltd Mr. Walter Perera
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: National Diploma in Engineering Sciences : Mechanical Engineering (General) : GIT (General Industrial Training) : 01/06/2012 - 31/07/2012 Swedish Trading Co. ltd Mr. Kapila Gunarathne
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Training Reports GIT at IET

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Training Reports GIT at IET

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NATIONAL DIPLOMA IN ENGINEERING SCIENCES

GENERAL INDUSTRIAL TRAINING REPORT

NATIONAL DIPLOMA IN ENGINEERING SCIENCES

Thank you, T.A.D.J.Chameera MG/09/7728

GENERAL INDUSTRIAL TRAINING REPORT

NATIONAL DIPLOMA IN ENGINEERING SCIENCES

2 SWEDISH TRADING COMPANY (Private) LIMITED

GENERAL INDUSTRIAL TRAINING REPORT

NATIONAL DIPLOMA IN ENGINEERING SCIENCES

ELASTOMERIC TECHNOLOGIES PVT (LTD)

GENERAL INDUSTRIAL TRAINING REPORT

NATIONAL DIPLOMA IN ENGINEERING SCIENCES

1.1.1 Functions of the organization

GENERAL INDUSTRIAL TRAINING REPORT

NATIONAL DIPLOMA IN ENGINEERING SCIENCES

GENERAL INDUSTRIAL TRAINING REPORT

NATIONAL DIPLOMA IN ENGINEERING SCIENCES

1.1.2 THE 5S CONCEPT

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1.1.3 ABOUT GASKETS

GENERAL INDUSTRIAL TRAINING REPORT

NATIONAL DIPLOMA IN ENGINEERING SCIENCES

GENERAL INDUSTRIAL TRAINING REPORT

NATIONAL DIPLOMA IN ENGINEERING SCIENCES

EXTRUDING (EXTRUDER) INSPECTION CUT TO SPECIFIED LENGTH

PACKAGING & FINAL INSPECTION

GENERAL INDUSTRIAL TRAINING REPORT

NATIONAL DIPLOMA IN ENGINEERING SCIENCES

1.2.0 MIXER AND MILL AREA

Compounding Ingredients Chemical plasticizer Filler Softeners Antidegradant Vulcanizing system

1.2.1 BATCH MIXER

GENERAL INDUSTRIAL TRAINING REPORT

NATIONAL DIPLOMA IN ENGINEERING SCIENCES

GENERAL INDUSTRIAL TRAINING REPORT

NATIONAL DIPLOMA IN ENGINEERING SCIENCES

1.2.2 TWO ROLL MILL

1.2.3 BATCH OFF

GENERAL INDUSTRIAL TRAINING REPORT

NATIONAL DIPLOMA IN ENGINEERING SCIENCES

GENERAL INDUSTRIAL TRAINING REPORT

NATIONAL DIPLOMA IN ENGINEERING SCIENCES

3.RESISTANCE TEMPERATURE DETECTOR (RTD)

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NATIONAL DIPLOMA IN ENGINEERING SCIENCES

1.3 EXTRUDER AREA

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NATIONAL DIPLOMA IN ENGINEERING SCIENCES

GENERAL INDUSTRIAL TRAINING REPORT

NATIONAL DIPLOMA IN ENGINEERING SCIENCES

1.3.2 ELECTRO MAGNETIC BREAKING SYSTEM

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NATIONAL DIPLOMA IN ENGINEERING SCIENCES

1.4. PRESS AREA

So the maximum clamping force = 824670kg

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NATIONAL DIPLOMA IN ENGINEERING SCIENCES

1.4.1 PRESSURE RELIEF VALVE

GENERAL INDUSTRIAL TRAINING REPORT

NATIONAL DIPLOMA IN ENGINEERING SCIENCES

The schematic of valve with a vent restrictor