Compression Machine FAT (Factory Acceptance Test)

Compression Machine FAT (Factory Acceptance Test)

Compression Machine FAT – The purpose is to identify the quality acceptance tests performed at the suppliers’ facilities. Ensuring the compression runs well at startup is an important role of the equipment supplier. Proper design and fabrication are critical, but equally important is a full shop performance test. performs a factory acceptance test on every compressor and dispenser we ship at the operating suction and discharge pressures at the site. also check control functions, wiring connections, compressor skid vibration, flow rates, and electrical loads.

machine name	:	35 STN “B” TOOLING TAB, COMPRESSION MACHINE
Client Name & address	:
document name	:	factory acceptance test
PROTOCAL no.	:
Revision no.	:	00
MACHINE SR. NO.	:

Table of Contents of Compression Machine FAT

1. SYSTEM DESCRIPTION

2. SYSTEM CHECKS

2.1 Physical Check

2.2 Basic Component Verification

3. VERIFICATION OF SAFETY AND INTERLOCK FEATURE

4. FUNCTIONAL VERIFICATION

4 .1 Basic Challenge Test

5. ACCESS LEVEL SECURITY

6. TRAIL REPORT

PERFORMANCE QUALIFICATION FOR TABLET COMPRESSION

 

SYSTEM DESCRIPTION: The major components of the equipment are identified us:-

• Powder Feeding unit.
• Powder transfer unit
• Compression unit
• Hydraulic power pack assembly
• Discharge unit
• Lubrication unit

The Tablet Compression B4 Type 35 Station. “B” Tooling Tab, Machine, supplied by ______________, a double rotary high-speed tablet press, is a machine incorporated with the force-feeding arrangement, auto-lubrication, electromagnetic clutch, power level sensor, and rejection/sampling port.

The powder feeding unit has an S.S. 316 Hopper capacity of 16 Liters. rests on top of the machine which holds the powder in it and delivers to the feeding assembly through a butterfly valve which controls the flow of the powder between the hopper and the feeding assembly. The hopper consists of an agitator, which enhances the powder flow. A barrel–type powder level sensor is mounted on a bracket and fixed against the sight glass of the hopper.

The powder transfer unit Consists S.S. 316 inlet connector, which links the hopper and the force feeder, the force feeder has two counter-rotating paddles of S.S. 316, driven by a reduction gearbox and variable frequency AC drive motor. The tail over die is an essential feature of the high–speed tablet press. The function of the tail-over die is to keep the filled die covered until the last moment before the upper punch enters the die.

The drive unit has a main motor of 5HP and drives a very high reduction gearbox unit using an electromagnetic clutch and a timing belt. The gearbox unit consists of a Phosphorus bronze worm wheel and a worm shaft. The turret is a three-piece structure having the center die tablet of S.S. 316 and upper and lower pieces of cast iron of SG 400/15. The upper piece holds the upper punches, which rest on the upper cam tracks with the cam plate. Similarly, the lower piece holds the lower punches that travel on the lower cam tracks and Dozer.

The compression unit comprises an upper main pressure roll assembly having a roll center, pressure roll, and pressure roll pin. The roll centre holds the pressure roll and is locked by using external circlips upper punch penetration assembly is responsible for the entry height of the upper punch in the die. Tablet thickness assembly is responsible in deciding the tablet thickness.

Weight dozer assembly is responsible for adjusting the weight of the tablet by varying the depth of fill. The depth of fill is adjusted by the upward and downward movement of the weight-adjusting head through a dozer-adjusting screw with the help of a dial.

The hydraulic power pack assembly system controls the safety overload mechanism, which governs the maximum pressure, and level, at which particular tablets are being made. The oil reservoir for this system is located in the front LH corner of the lower cabinet. It can be accessed by removing the lower side guard (LH). The oil level in the reservoir should be checked regularly through the oil level indicator.

The tablet discharge unit comprises of ejection cam, tablet scrapper assembly & tablet discharge chute. The height of the ejection cam needs to be set in such a way that the tip of the lower punch is slightly above the die so as to avoid tablet-chipping problems. As soon as the tablet is ejected it strikes the tablet scrapper assembly, which directs the tablet to the discharge chute. The tablet discharge chute is made S.S. 316 with an acrylic cover. Tablets slide out through this chute to the container.

Auto lubrication system is provided for the lubrication of all critical pinpoints like roll pins, it comprises a lubrication tank, a motorized pump, distribution manifold, and pipelines. This pump operates on a timer set in the PLC. It should be noted that the ON time should be less than the OFF time, to prevent oil flooding. The dozing of oil’s respective critical points can be throttled through the distribution manifold.

The lower punch lubrication system helps mainly for smooth and easy ejection of tablets. In addition, the tablet gets a clean, smooth surface on the web. The lower punch has an extractor groove below the tip for the lubrication support, which may be a lubrication felt or woolen thread winding. In order to avoid lubricant, the scraper mechanism is built in. The stripper oil is collected in a collecting tray. The scraper keeps the external diameter of the die plate and lower punch guide clean. From the collecting tray, the oil is transported downward through a funnel and a hose line and returned back into the tank.

The working principle of compaction force control is whenever the powder is compressed from a tablet an impact is generated. The oil in the hydraulic cylinder absorbs this impact. The load cell, which is mounted between the upper roll lever and the hydraulic cylinder, senses the load received. The value is transferred to the data control screen through the MP55 transducer and the PLC. The data control screen displays the individual force of all the punches.

 SYSTEM CHECKED DURING COMPRESSION MACHINE FAT:

2.1 Physical Check :

Method	Description	Acceptance Criteria
Outer Surface finish verification	Check the Outer surface of the machine	-Matt finish -Curved corner -No dent -No visible spot of welding
AC/DC panel checking	Visual check	-Should be available -Proper wiring
Document verification	Verification of calibration certificate of Digital Pressure Indicator and Pressure Gauge.	-Calibration certificate should be available
Document verification	Verification of MOC certificate	-MOC certificate should be available

 2.2 Basic Component Verification :

Sr. No.	Test Description	Acceptance Criteria	Test Method	Acceptance Criteria fulfilled
l	Machine Dimensions	1880 (L) X 2040 (W) X 2000 (H)MM	Machine Dimensions	□ Yes □ No
l	G.A. Drawing	l   Machine construction should meet with G.A. drawing.	□ Visually □ Via Tag	□ Yes □ No
l	Main switch (ON/OFF)	ON/ OFF function l   Qty.: 01 no.	□ Visually □ Via Tag	□ Yes □ No
l	Emergency switch (ON/OFF)	l   Make: Banner l   Qty.: 1 No.	□ Visually □ Via Tag	□ Yes □ No

Compression Machine IQ (Installation Qualification)

Sr. No.	Test Description	Acceptance Criteria	Test Method	Acceptance Criteria fulfilled
ELECTRIC MOTORS (MAIN MOTOR)
l	MAKE	CROMPTON	□ Visually □ Via Tag	□ Yes □ No
l	SR. NO.		□ Visually □ Via Tag	□ Yes □ No
l	RPM	1440	□ Visually □ Via Tag	□ Yes □ No
l	VOLTAGE	415 V	□ Visually □ Via Tag	□ Yes □ No
l	HP/KW	5HP./3.3KW/ FOOT MOUNTED	□ Visually □ Via Tag	□ Yes □ No
l	PHASE	3 PH	□ Visually □ Via Tag	□ Yes □ No
l	FREQUENCY	50 Hz	□ Visually □ Via Tag	□ Yes □ No

 

Sr. No.	Test Description	Acceptance Criteria	Test Method	Acceptance Criteria fulfilled
AC VARIABLE FREQUENCY DRIVE FOR MAIN MOTOR
l	MAKE		□ Visually □ Via Tag	□ Yes □ No
l	MOTOR RATING	5 HP	□ Visually □ Via Tag	□ Yes □ No
l	MODEL		□ Visually □ Via Tag	□ Yes □ No
l	SR. NO.		□ Visually □ Via Tag	□ Yes □ No
GEARBOX [MAIN DRIVE]
l	MANUFACTURE	FALCON	□ Visually □ Via Tag	□ Yes □ No
l	TYPE	WORM & TEETH RING	□ Visually □ Via Tag	□ Yes □ No
l	REDUCTION STAGE	SINGLE	□ Visually □ Via Tag	□ Yes □ No

 

Sr. No.	Test Description	Acceptance Criteria	Test Method	Acceptance Criteria fulfilled
LUBRICATION OIL PUMP
l	MANUFACTURE	DROPCO ENG	□ Visually □ Via Tag	□ Yes □ No
l	MODEL	DMHT-600-5 (Dx)	□ Visually □ Via Tag	□ Yes □ No
l	LUBRICATION SYSTEM	ONE SHOT LUBRICATION (MANUAL HANDEL TYPE PUMP)	□ Visually □ Via Tag	□ Yes □ No

3. VERIFICATION OF SAFETY AND INTERLOCK FEATURE DURING COMPRESSION MACHINE FAT :

Sr. No.	Test Description	Acceptance criteria	Observation
l	Emergency Stop	“Emergency Stop Activated” Alarm message should display on the monitor screen and the inspection will stop. The tower lamp should glow with red color and the buzzer should get ON.

4.FUNCTIONAL VERIFICATION DURING COMPRESSION OF MACHINE FAT  :

4 .1 Basic Challenge Test Compression Machine FAT:

Sr. No.	Test	System Result	Remedial Action
1	Upper guards [when interlock mode is selected for machine function]	Open any of the upper guard	The machine will stop immediately and can not be restarted till the guard is open  guard open indicator lamp will be “on”
2	Main pressure overload	Increase depth of fill and/or decrease tablet thickness either L.H.S. OR R.H.S.	The main set pressure overload indicator lamp will be “on”
3	At the time of providing the password if the admin set the password in a non-alphanumeric nature	“Password should be min 8 characters and must contain at least one number, small case letter, upper case letter, and each” Message should be displayed.	Provide password as per note given on system display
4	At the time of providing the password if the admin sets the password to less than 8 8-digit	“Password should be min 8 characters and must contain at least one number, small case letter, upper case letter, and each” message appears on the screen.	Provide password as per note given on system display
5	If the user expires by date	“USER: USER1 password has expired. Do you want to change the password”. The message should be displayed on the screen.	Contact to admin and Renew the date from your admin
6	At the time of login if you enter 3 times wrong password	“your account has been locked. Please contact to admin to unlock” message should be displayed on the screen.	Contact to admin and unlock the account from your account
7	Power Failure	The machine stopped and after resuming power should not lose the data.	Power Backup Facility (UPS)

5.0 ACCESS LEVEL SECURITY:

Sr. No	Feature	Acceptance Criteria
1	Admin	The system should allow to creation of 30 Admin
2	Supervisor	The system should allow to creation of 30 Supervisor
3	Operator	The system should allow to creation 50 Operator

 6.0 TRAIL REPORT OF COMPRESSION OF MACHINE FAT :

Machine Operational & Performance Verification (Trial- I):

Machine Speed (RPM)	Trial	Weight Variation		Friability (% w/w)	Hardness (Kg/cm2)	Thickness (mm)
		Wt. of 20 Tablets         (gm)	Individual* (mg)
		NMT ±2% of target weight	NMT ±5% of target weight	NMT 1%	NLT 2.0 Kg	To monitor
5	Sample #1
	Sample #2
	Sample #3

Machine Operational & Performance Verification (Trial- II) COMPRESSION OF MACHINE FAT

Machine Speed (RPM)	Trial	Weight Variation		Friability (% w/w)	Hardness (Kg/cm2)	Thickness (mm)
		Wt. of 20 Tablets         (gm)	Individual* (mg)
		NMT ±2% of target weight	NMT ±5% of target weight	NMT 1%	NLT 2.0 Kg	To monitor
15	Sample #1
	Sample #2
	Sample #3

Machine Operational & Performance Verification (Trial- III):

Machine Speed (RPM)	Trial	Weight Variation		Friability (% w/w)	Hardness (Kg/cm2)	Thickness (mm)
		Wt. of 20 Tablets         (gm)	Individual* (mg)
		NMT ±2% of target weight	NMT ±5% of target weight	NMT 1%	NLT 2.0 Kg	To monitor
25	Sample #1
	Sample #2
	Sample #3

7. SUPPLIER & CLIENT REMARK:

SUPPLIER REMARK :___________________________(Sign/date)

CLIENT REMARK :___________________________ (Sign/date)

Sr. No.	CLIENT		SUPPLIER
	Name	Sign & Date	Name	Sign & Date

Compression Machine IQ (Installation Qualification)