322
5.1
PROCESS INSTRUMENTATION
L T P
3 - 3
RATIONALE
This subject gives the knowledge of various instruments used to measure various process
parameters. This course will impart knowledge on working principle, construction, repair
and use of these instruments
DETAILED CONTENTS
1.
Introduction
(25 hrs)
Importance of instrument in chemical process industry, general classification of
instruments, indicating and recording type instruments, static and dynamic
characteristics of instrument, description and construction details, working
principle, range and application of following instrument:
2.
a)
Pressure and vacuum gauge: liquid column gauge, bourden tube gauge
b)
Thermometer and Pyrometer: liquid expansion thermometer, bimetallic
thermometer, thermocouple, resistance thermometer, optical and radiation
pyrometer
c)
Liquid level meter: visual indicator, float actuated level meter, static
pressure instrument
d)
Flow meters: Orifice, venturi, pitot tube, rotameter
e)
Analysers: pH meter, chemical composition analyzer, various types of
analyzer i.e. oxygen analyzer, infra red analyzer, orsat analyzer
Transmission
(04 hrs)
Pneumatic and electrical transmission (Induction Transmission only) and their
field of application
3.
Process Instrumentation
(05 hrs)
Transmission of instrument reading, control centre, instrument diagram,
instrumentation in modern chemical plant
4.
Basic concept of automatic process control, advantages of automatic control
(05 hrs)
5.
Types of controllers, classification of controllers like pneumatics, electronic,
hydraulic and their applications in chemical industry
(07 hrs)
6.
Types of control valves
(02 hrs)
323
LIST OF PRACTICALS
1.
Calibration of pressure gauge/vacuum gauge
2.
Calibration of resistance thermometer
3.
Calibration of thermocouple
4.
Characteristics of a flapper nozzle system
5.
Study of on-off controller for temperature control
6.
Study of constructional detail of chart recorder
7.
Study of constructional details of strip chart recorder
8.
Composition analysis by using pH meter/conductivity meter
9.
Study the characteristics of pneumatic control valve
INSTRUCTIONAL STRATEGY
The subject gives the knowledge of various process controls to measure process
parameters. So the theoretical knowledge of this subject should be properly imparted to
the students with the help of practical examples. Each topic should be supplemented with
examples.
RECOMMENDED BOOKS
1.
Industrial Instrumentation by Donald P Eckman, Wiley Eastern Publication
2.
Principles of Industrial Instrumentation by D Patranabis, Tata McGraw Hill
Publication
3.
Process System Analysis and Control by Coughnour, McGraw Hill Publication
4.
Industrial Instrumentation by SK Singh, Tata McGraw Hill Publication
SUGGESTED DISTRIBUTION OF MARKS
Topic No.
1
2
3
4
5
6
Total
Time Allotted (Hrs)
25
04
05
05
07
02
48
Marks Allotted (%)
40
20
10
10
10
10
100
324
5.2
REPAIR AND MAINTENANCE OF PLASTICS MACHINES
L T P
3 - 3
RATIONALE
Most of the diploma holders get employment in plastic processing industry, where they
operate processing machinery and manage production. The purpose of this subject is to
equip the students with the knowledge of repair and maintenance of such machines and
equipments.
DETAILED CONTENTS
1.
Electrical Repair and Maintenance
(05 hrs)
Shm’s Law, Kirchoff’s Law, Wheatstone bridge. Series and parallel connections
of resistance, effect of temperature on resistance, capacitor, types of capacitors,
series and parallel connections of capacitors, Faraday’s Law of electromagnetic
induction.
2.
Electrical Controls
(03 hrs)
Galvanometer, ampere meter, volt meter, shunt and wound, multimedia and
pressure transducers.
3.
Protective devices
(03 hrs)
Relays switches, timers, temperature controllers, limit switches, heaters, study of
electrical circuits, MCB, OCB, ABCB
4.
Electric Motors
(10 hrs)
Introduction motor, Synchronizing motor, DC motor, AC/DC Motor, servo motor,
starter winding, armative winding, motor starter, star and delta connection, motor
coupling.
5.
Semi Conductors
(03 hrs)
P & N type Semiconductor, PN Junction diode, Zenner diode, Transistor (PNP
and NPN), mligrated circuits.
6.
Safety Rules and Regulator
(02 hrs)
Earthing and its importance, coontrol pannel, signals and its types, alarms, safety
fuses and types of fuses, electrical insulations
7.
Fault finding and repair in Plastic machines and their remedies.
(03 hrs)
8.
Preventive and Breakdown maintenance
(03 hrs)
325
Advantages and disadvantages of maintenance, purpose of maintenance
9.
Concepts of hydraulics
(04 hrs)
Principle of hydraulics, merits and demerits of hydraulics pumps
10.
Hydraulics Motors
(06 hrs)
Inline Piston Motors, Bent Axis piston motors, vane motor, positive and variable
hydraulics motors
11.
Hydraulics Circuits and Lubrication
(06 hrs)
Circuits for injection moulding machines, hydraulic symbols, Industrial hydraulic
Circuits
Lubrication system, oil seals, o-rings, types of lubricants grease, effect of
temperature on lubricants, Air break valve filters, strainers, oil filters
LIST OF PRACTICALS
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
To study the temperature controller and thermocouple.
To study the circuit brakers
To study the relays
To make a circuit for conversion of AC to DC
Series and parallel connection study for resistance and capacitor
To study the limit switches
To study the heater wire and its capacity
To study the fault finding in plastic machines
Installation / erection of plastic machines, alignment of various equipments.
Bearing/bush fitting and other procedure of fitting.
Assembling of Gear Box
To study chilling plants
To study filters, oil seals and o-ring
To study various pump repairs
To study various valve repair
INSTRUCTIONAL STRATEGY
Students should be asked to do small repairs in the laboratories.
RECOMMENDED BOOKS
1.
2.
3.
Fundamentals of Electrical and Electronics Technology by B.L. Thereja
Electrical Wiring Estimation and Costing by JB Gupta .
Electrical Engineering by KD Sharma
326
4.
5.
6.
7.
8.
9.
10.
11.
12.
Electronics Devices and Circuits by J. Millman and CC Halkias.
Basic Electrical Engineering by Kastkin A and Perikatin, M.
Hydraulic manual by Vickers
Mechanical design By R.S. Khurmi
Production Technology By HMT
Guide to machine tools By IMTMA
Preventive maintenance by APTE
Workshop Technology Vol.I and IV By Hajra Chowdhury
Machinery hand book by ITB
SUGGESTED DISTRIBUTION OF MARKS
Topic No.
1
2
3
4
5
6
7
8
9
10
11
Total
Time Allotted (Hrs)
05
03
03
10
03
02
03
03
04
06
06
48
Marks Allotted (%)
10
05
05
20
10
05
05
05
05
15
15
100
327
5.3
COMPUTER APPLICATION IN PLASTIC INDUSTRY
L T P
- - 6
RATIONALE
During the past decade, the use of computers in education has been growing at fast rate.
The time has now come when engineering technician has to familiarize himself with
computers to enable him to cope with inevitable computerization of a significant portion
of his job. This subject is very helpful for the students who want to pursue their carrier in
the field of designing.
DETAILED CONTENTS
Specific Applications for Plastic Industry
1.
Core and Cavity: A simple two plate mold design, analyzing draft on a model, the
mold design process, scale the part for shrinkage, determine the parting lines,
manual selection of parting lines, smoothing the parting surfaces, automation,
modeling the parting surfaces, interlocking the mold tooling, creating the mold
tooling.
2.
Repairs snd Surfaces: creating new drafted faces, complex shut off surfaces,
interlock surfaces.
3.
Multiple Parting Directions: Multiple parting directions, Trapped molding areas,
side cores, Lifters, core pins, Electrode design, electrode clearances, keeping the
sharp edges.
4.
Alternate Methods for Mold Design: Alternate methods for mold design using
combine and split, using surfaces, using up to surface method, using the split
method.
5.
Design Validation: Linear static analysis, model analysis on assemblies and part, ,
finite element modeling and model check, sample liner static analysis.
6.
Mould Manufacturing: Introduction to DEPO CAM, Basics of CAM and
programming, planer milling programs and set up creation, simple milling
exercise, introduction to three axis milling, three axis milling exercise.
RECOMMENDED SOFTWARE
1.
2.
Solid works/cosmos works
I-mould.
328
5.4
PLASTIC PROCESSING TECHNIQUES - III
L T
4 -
P
4
RATIONALE
The purpose of this subject is to equip the students with the knowledge of compression
moudling, calendaring, casting etc. This subject develops the competence of the students
in major industrially practiced processing techniques.
DETAILED CONTENTS
1.
Compression and transfer moulding
(16 hrs)
General principles, limitation in using thermoplastics, bulk factor, perform and
their uses. Compression moulding machine, (hand compression and
semiautomatic) specifications of machine, day light (single and multi day light)
hydraulic system, preheating cycle time, advantages of multiple cavity mould,
process variables and their control, faults and remedies, comparison of
compression and transfer moulding.
2.
Forming
(12 hrs)
Thermoforming and vacuum forming basic methods, laminate forming, high
pressure and low pressure laminates, types of sheets, multi product formation,
fault and remedies.
3.
Calendaring
(12 hrs)
Process, material used, advantages of calendaring over extrusion, types of
calendar, coating by calendaring, surface finishing
4.
FRP
(12 hrs)
Introduction, different processes used in FRP, advantages of FRP, different types
fillers used in FRP (Carbon fibers, boron fibers, natural fibers, manmade fibers,
glass fibers and fibre materials)
5.
Casting
(12 hrs)
Introduction, different processes of casting, materials used in casting, advantages
of casting, faults and remedies
LIST OF PRACTICALS
1.
To study the moulding of various products by compression moulding
2.
To study the compression moulding machines
329
3.
To study the moulding of various products by Transfer moulding
4.
To study the Transfer moulding machines
5.
To study the vaccum forming machine and make a product using this machine.
6.
To study the thermoforming machine and make product on this machine
7.
To study the casting of nylon/anylin/polyster materials
8.
To study the process of FRP and make a product using hand lay up process
9.
To make a sheet using the process of calendaring
10.
To study the effect of various parameters on compression and transfer molulding
INSTRUCTIONAL STRATEGY
Local industry visit should be undertaken.
RECOMMENDED BOOKS
1.
SPI Engineering Hand book by Frados
2.
Plastic processing by Radian
3.
Moulding of plastics by NM Bekalis
4.
Plastic Engineering Hand book by Michael L. Berins
5.
Plastic processing Data Hand book by Rosato and Rosato
6.
Plastic processing by Groth and Schott
7.
Surface coatings by Swaraj Paul.
SUGGESTED DISTRIBUTION OF MARKS
Topic No.
1
2
3
4
5
Total
Time Allotted (Hrs)
16
12
12
12
12
64
Marks Allotted (%)
35
20
15
15
15
100
330
5.5
MOULD DESIGN-III
L T
3 -
P
4
RATIONALE
A diploma holder in Plastic Technology is engaged in manufacturing Plastic componentss
for which design of moulds and dies is essential. This subject will impart them requisite
knowledge and skills in design of moulds and dies.
DETAILED CONTENTS
1.
Compression moulds: Method of feeding by weights, by volume and pellets or pre
form.
(04 hrs)
2.
Multi impression compression mould: cavity calculation and number of
impression: curing time, breathing time, Temperature range.
(08 hrs)
3.
Types of compression mould: Positive, semi positive and open flash type mould.
(04 hrs)
4.
Transfer mould: Its type, pot type, plunger type (bottom plunger & top plunger)
requirement of transfer mould over compression mould, pot calculation, cull, bulk
factor.
(08 hrs)
5.
Methods of moulds heating : By filament heater, cartage heater, band heater,
indction heating, oil heating, calculation for heating cap.
(08 hrs)
6.
Blow mould: extrusion blow mould, design of blow mould, neck, cavity and
pinch-off. mould shrinkage: mould cooling and different mould material
(ferrous and nonferrous)
(08 hrs)
7.
Stretch blow mould: Pre-form and its design , neck and cavity design.
(08 hrs)
LIST OF PRACTICALS (Minimum Drawings Sheets 8)
1.
Compression mould design, positive and semi-positive and open flash type with
detail and assembly.
2.
Transfer mould design with detail and assembly.
3.
Blow mould design with detail and assembly.
331
INSTRUCTIONAL STRATEGY
Students should take practical knowledge and design of electrical switches, pet bottles
and other liquid packaging bottles.
LIST OF RECOMMENDED BOOKS
1.
Compression and Transfer Moulding, by Bobb
2.
Injection and Transfer Moulding and Plastic Mould Design, by Boven and
Robinson.
3.
Plastic Processing Data Handbook by Rosato and Rosato.
4.
Blow Moulding by Fischer, Itiffe London, Publication.
5.
Extrusion of Plastics by Fisher, Itiffe Landon Publication
SUGGESTED DISTRIBUTION OF MARKS
Topic No.
1
2
3
4
5
6
7
Total
Time Allotted (Hrs)
04
08
04
08
08
08
08
48
Marks Allotted (%)
10
15
10
15
15
15
20
100
332
5.6
ENGINEERING AND SPECIALITY POLYMERS
L T
4 -
P
-
RATIONALE
This subject gives a detailed description of polymeric materials in category of
thermoplastics, thermosets and thermoplastic elastomers. The students acquires the
knowledge of advanced engineering and speciality polymers so that he/she can select the
right type of materials for processing to make the product.
DETAILED CONTENTS
1.
Advanced thermosets, epoxies, poly urethanes
(10 hrs)
2.
Engineering thermoplastics – poly carbonates, polyamides, PEEK, poly
phenylene oxide, acetals
(10 hrs)
3.
Reinforced plastics – principles of composite reinforcement, effect of
reinforcement on strength of plastics. Role and nature of binders and
coupling agents, properties and applications of fibres in reinforcement
(glass and carbon). Miscellaneous fillers (Talc, mica, Calcium
Carbonate CaCo3, glass, beads). Properties and applications of FRPs
(un-saturated polyesters, epoxies, PU, nylon)
(14 hrs)
4.
Polyblends and alloys – Definition, advantages of polymers, blends and
alloys, role of composition, properties and applications of parameters
for compability, PVC – Nitrile rubber, ABS-PVC and PP-EPDM
(06 hrs)
5.
High performance polymers – polytetrafluroethylene,
polysulphones, liquid crystalline polymers
Teflon,
(10 hrs)
6.
Preliminary concept of new materials such as conducting polymers, biopolymers, onto-electronic plastics, nano-polymeric materials and
plastics in biomedical applications, interpenetrating polymer networks,
polymer concretes
(14 hrs)
INSTRUCTIONAL STRATEGY
Speciality polymers should be shown to the students in the classroom or the products
manufactured from them.
RECOMMENDED BOOKS
1.
2.
Polymer Science & Technology by Premamoy Ghosh
Polymer Blends and Alloys by Arends
333
3.
Polymers Science & Technology by JR Fried
4.
Plastics Materials by Brydson, PHI Publication
5.
Engineering Polymers by Dyson, PHI Publication
5.
Polymer Materials and Processing by Jean Michael Charrier
SUGGESTED DISTRIBUTION OF MARKS
Topic No.
1
2
3
4
5
6
Total
Time Allotted (Hrs)
10
10
14
06
10
14
64
Marks Allotted (%)
10
15
25
10
15
25
100