Final Report

GRADUATE ACT. APPRENTICESHIP TRAINING

(28Th OCTOBER 2014 – 28Th OCTOBER 2015)

S.ARUN Employee No: 600317

B.E & Diploma – ELECTRONICS AND COMMUNICATION

ENGINNERING

SRF LIMITED – TECHNICAL TEXTILES BUSINESS MANALI

ACKNOWLEDGEMENT

I am immensely grateful to Mr. V. Sekar (Senior Vice President-Operations &

complex heads office), SRF LIMITED TTB-Manali, Chennai, for providing the opportunity

to get trained and learn in this premier organization.

I am immensely thankful to Mr. Narayanan Athmanathan (Deputy General

Manager) for providing the opportunity and required facilities.

I am immensely thankful to Mr. KALAI SELVAN (Chief Manager) HR for

providing the opportunity and required facilities.

I express my gratitude and sincere thanks to Mr. VIVEK SINGH SENGAR- Chief

Manager (Instrumentation) for his co-operation, invaluable guidance and motivation.

I am indebted to [Mr.S.Arunarokiadass, Assistant Manager, Mr.Suvajit Roy, senior

Executive] of Instrumentation department, for his invaluable support and supervision

throughout the training period, which had kept this training on track.

In the course of training at SRF Limited- TTBM, I had learnt a lot about this

organization and also about the latest on goings and development in Instrumentation field. I

express my sincere thanks to all the members who have helped directly and indirectly.

Without their help and guidance I wouldn’t have been able to successfully complete my

training worth fully.

CERTIFICATE

This hereby certify that the work which is being presented for the award of

Apprentice Certificate, submitted at SRF Limited, Manali is an authentic record of Mr.S.ARUN carried out under the supervision of Mr. VIVEK SINGH

SENGAR, Chief Manager of (Instrumentation).

This certification represents excellence in his learning skills also represents

his attitude, obedient and sincerely in his work and the way he towards involving himself in mixing up with high standards and self-responsibilities and progress

through success and knowledge.

He also serviced electronics’ and instrument’s which are added in the list.

This is to certify that the above statement made by the candidate is correct to the best of my knowledge.

(Mr. Vivek Singh Sengar)

Chief Manager - Instrumentation

SRF Limited-TTBM

Chennai – 600068.

SRF LIMITED

PROFILE:

The SRF is a multi-business entity engaged in the manufacturing of chemical based

industrial intermediates. Established in 1973, SRF has today grown into a global enterprise

with operations in 4 countries. With headquarters in Gurgaon, India, the $450 million company

has operations in three more countries, UAE, Thailand and South Africa. Apart from Technica l

Textiles Business, in which it enjoys a global leadership position, SRF is a domestic leader in

Refrigerants, Engineering Plastics and Industrial Yarns as well. The company also enjoys a

significant presence among the key domestic manufacturers of Polyester Films and

Fluorospecialities.

Building on its in-house R&D facilities for Technical Textiles Business and Chemica ls

Business, the company strives to stay ahead in business through innovations in operations and

product development.

A winner of the prestigious Deming Application Prize for its tyre cord business, SRF continues

to redefine its work and corporate culture with the TQM as its management way.

SRF Today - a snapshot

Rs. 2000 crore multi-product, multi-business organizations.

Market leader in Technical Textiles, Refrigerants, Engineering Plastics and Industria l

Yarns.

Manufacturing plants spread over 8 locations in India, one in Dubai, one in South Africa

and one in Thailand.

World's 2nd largest producer of Nylon 6 tyre cord fabrics.

World's 2nd largest producer of belting fabrics.

Exporting to over 60 countries.

Process Overview

Capro Lactam Chips Yarn Undipped Fabric

Molten Lactam Additives Ply Dipped Fabric

Polymer Polymer Cord Tyre Cord fabric

Chips Yarn Fabric

Polymerization

Dipping

Spinning

Twisting and Loom

NEW YARN PLANT - POLYMERIZATION:

The NYP Ploy plant is the first stage, where the raw material “caprolactam”

is fed, treated at confined conditions then made into polymer and pelletized into polymer chips

stored in the silos.

Instrumentation plays a vital role in this plant with high end technology, because the

plant uses most of the transmitters and control valves of “FOUNDATION Fieldbus”

technology; which is all digital, duplex, self-diagnostics and multidrop technology and

“Profibus” for drives with “DELTA V” DCS. Also it uses conventional on/off valves,

temperature sensing elements etc.

The temperature in the entire process should be maintained at the specified limits and

the product should not be oxidized, so as to maintain the quality of the final product. The entire

process involves mainly closed loops which are feedback type; also the process has multip le

interlocks for safe operation.

The entire plant is controlled by three DELTA V MD controllers (1, 2, 3) where

controller 1 is assigned to discrete instruments, controller 2 is assigned to analog instruments

and the controller is assigned to De-Polymerization area. The entire plant is operated by 2

Operator Work Stations (OWS), which is controlled by a Professional plus station (DVINST).

The process parameters such as pressure, level and DP flow where measured using the

Rosemount 3051(FF) type transmitters and Yokogawa D-Harp type etc. Mass flow is measured

using the multi parameter measuring Micro Motion F-series (FF) Coriolis sensors and 2700

Micro Motion transmitters. The magnetic flow meters are of Rosemount 8742C

(FF)Most of the control valves are of Samson 3730-5 (FF) make. The point level is measured

using vibrating fork and capacitance type level switches of Sapcon make, and uses temperature

sensors such as PT100, K type thermocouples and also other instruments such Trace Oxygen

analysers, Solenoid valves, Rotameter’ s etc.,.

NEW YARN PLANT - SPINNING:

The NYP Spinning is the second stage of the process, where the polymer

chips mixed with CUI then heated and melted at specified temperature and pressure then

quenched and made into fine filaments of yarn and rolled up in the bobbins. The plant is in

technical collaboration with TMT Machinery Co, Japan.

There are four chip receiving silos, the chips from the silos in poly are transferred to

the nine unit’s CRS1 through the Nitrogen pressure and it is incorporated with vibrating fork

level switches so as to indicate the level. Then the chips are mixed in 20(Chips):4(CUI) ratio

in the ASM area which is controlled by a Siemens S7 PLC, the inputs and outputs are connected

to the DCS through the Remote I/O sub-system 1. The load in the hoppers are measured by

load cells A-stuff (S type), B-stuff (Single Ended) then mixed and fed to CRS 2.the CRS 2 &

3 are maintained at below atmospheric pressure. Also these silos have pressure switches,

gauges, vibrating fork level switches and solenoid valves etc. which are connected to the DCS

through the Remote I/O sub-system 2 and connected DCS through controllers 6 & 7 and the

process is operated by 1 Operator Work Station(OWS).

The chips from the silos are fed to the Extruders (JSW) where the polymer chips are

melted at high pressure and made as fine yarn filaments, which is quenched to increase its

strength. The extruders has point temperature, pressure measurements where all instruments

are connected to remote junction boxes to the individual cards connected in the CAN Network

and DeviceNet connects the cards to the OMRON PLC for control. The RTD's are from ozaki

and the pressure transmitters are Nagano Keiki.

Then the chips are extruded into filaments of required denier. This filament, immedia te ly

after extrusion is wound on bobbins after a coat of spin finish oil. This is called undrawn

yarn and given to winders, where it is winded in the bobbins.

TEXTLIES:

The textiles have two stages of product output Twisting Weaving.

The undrawn yarn is stretched about 5 times under elevated temperature conditions to

improve molecular orientation of the yarn in Draw Twisters (DT). This yarn is called drawn

yarn. Here in the DT the temperature is the main process control objective which is sensed

by the RTD’s and controlled individual controllers for each DT, also there are SSR’s for

high speed output isolated switching, MMI for 1&2 and 3&4 DT. The temperature and RH

of the hall is monitored by Abus transmitter and indicated to a local display.

The drawn yarn is twisted in the machine called ply twister in a definite twist per

meter (TPM) in the direction (S) as per the customer requirement. In the machine Cable

Twister double or triple runs of ply twisted yarn are twisted in the opposite (Z) direction. This

product is called Nylon Tyre Cord. Here the length counter of mechanical type is used as

the product length reference.

In the machine called Loom, the Nylon cords are woven into fabric. Here the Nylon

Tyre Cord is the warp and the interlaced cotton yarn used as weft. There are nearly 15

looms and each loom has individual high end control system, the control is carried out by

the CAN bus and OFC, then it has single ended load cells, motorised solenoid valves in

Fixed & Relay nozzles, hand safety sensors, air regulators, length counter, solenoid valves

etc.

DIPPING:

Dipping is the process of coating greige fabric in 40% rubber latex with a solut ion

of resorcinol and formaldehyde. This process brings about strong adhesion between the rubber

compound (tyre) and the fabric. There are two new driers (1A &1B) of six zones and four old

driers (D1, D2, D3 and D4) of four zones.

Each drier has to maintain the temperature within the specified limits so as to achieve

the product quality, a Siemens S7 PLC acts as master for each unit and also to the sequence

controller. The sequence controller is of ESA-pyronics make which gives appropriate signal

to the step up transformer (for the spark plug) and also gives necessary control signals to the

modulation motor (Gastechnic) and solenoid valves for ignition.

The ignition is sensed by the UV flame sensor (ESA-pyronics) and given to the

sequence controller; also there are pressure switches for sequence operation, such as exhaust

air, fresh air, gas+air switches. Rather than this there are load cells (HBM, E+L etc.) which

are used for the web tension monitoring and control of the PRS motor and rollers. There are

also Sensors for the fabric width adjustments such as Duo canter, Trio canter etc.

UTILITIES:

There are five Fuel Oil Boilers and three Steam Boilers of which one is husk feeding

and other two are oil fired boilers. The husk boiler is of 12 ton capacity and the control loops

are of single loop electronic control. The bed temperature is monitored by the thermocoup les

(K- type), the drum level and pressure are measured by the Rosemount (1151 smart)

transmitters, there are pressure switch for pressure safety interlock, mobrey level switch for

level safety interlock, safety relief valves, solenoid valves for sequential bag filter operation.

The SPM analyser is of optical type and used to continuously monitor and record the data’s

this is of Forbes Marshall Codel type installed in the both of the stack.

Effluent treatment Plant will collect all the waste water in and around the plant then

process it by adding chemicals and aerating it and then gives the processed water to the water

treatment plant and the slug to the sewage. There are float type level switches, Magnetic Flow

meters (krohne Marshall) for monitoring flow and a Dissolved oxygen analyser (LDO) Hach

make used to find the oxygen levels in the aerator pond and issues the control signals to the

drives of the blowers so as to control the oxygen levels. The water treatment plant is associated

with RO plant and there are NAMUR types of on/off valves, displacer type of level switches,

E+H Magnetic Flow meters (Promag), Rotameter’ s, pressure switches etc.

There are three Ingersoll Rand (centac) centrifugal 3 stages Compressor’s, three diesel

compressors which are auto start when the pressure in receiver goes down, and kosla

compressors. The inlet and exhaust air flow to the compressor is controlled by the Split range

control action by the microprocessor based controller; also the compressor is associated with

instruments such as vibration sensors, pressure switches, and temperature switches etc., for

control actions.

INTRODUCTION

Purpose:

To provide a suitable industrial experience to an engineering professional with

necessary training in the field of Instrumentation along with TQM, Documentation activit ies

and SERVICING With high level of knowledge and discipline.

So as to improve the knowledge and skill level with good attitude.

Features:

This training feature in maintenance activities in and around the plant and

documentation work carried out in the Instrumentation Department of SRF Limited-TTBM, a

premier Tyre Cord manufacturing facility in India to understand the realities, infrastructure of

process industries.

To get educated about instruments that are dedicated to measure, monitor, record

and control so as to obtain optimum results. Instruments the heart of every industry which plays

a vital role in the process control applications, especially primary measuring instruments such

as transmitters, sensors, primary sensing elements then control equipment’s such as single loop

controllers, PLC, DCS etc., and bus networks such as FOUNDATION Fieldbus, Profibus,

CAN Bus, Device Net, etc.,

INSTRUMENTATION

Instrumentation is an art of science, which involves measurement,

monitor and control of physical parameters such as pressure, temperature, flow, level, pH etc.

so as to improve product quality to get optimum output. The technology in this field continues

to a rapid development with intelligent electronics and software’s to the instrument systems.

Pressure:

The force per unit area is called the pressure.

We could represent this as:

Pressure = Force / Unit Area

A gauge pressure device will indicate zero pressure when bled down to Atmospheric

pressure. Absolute pressure includes the effect of atmospheric pressure with the gauge

pressure.

Absolute Pressure = Gauge Pressure + Atmospheric Pressure

The units of measurement are either in pounds per square inch (PSI), kg/cm, Pascal, etc.

Measuring Instrument:

Pressure gauge, Mano meter, pressure transmitter, pressure switch, etc.

Temperature:

Temperature can be defined as degrees of hotness and coldness of an object or a

substance which are expressed according to a comparative scale and shown by a thermometer

or perceived by touch.

The units of measurement are either in degree scale, Celsius, Fahrenheit, kelvin, etc.

Flow:

Flow of a (liquid, gas or electricity) move steadily and continuously process of flowing

any liquid.

Go from one place to another in a steady stream, typically in large numbers.

Flow is directly proportional to the square root of differential pressure created or

caused by (orifice, venture tubes, etc.

Mathematically:

Where,

F – Flow

K – Constant

P1, p2 – DP (differential pressure / sqrt (square root).

The units of measurement are either in m3 per hour, newton, etc.

Measuring Instrument:

Orifice Plate, Rotameter, magnetic flow transmitter, mass flow transmitter, etc.

Differential pressure:

D.P is the pressure between suction pressure between suction pressure and

discharge pressure.

D.P can be created or caused using orifice plates, venturi tubes etc.

Bourdon Tubes Pressure gauge:

Bourdon tubes are circular-shaped tubes with oval cross sections. The pressure

of the medium acts on the inside of the tube. The outward pressure on the oval cross section forces it to become rounded. Because of the curvature of the tube ring, the bourdon tube then

bends as indicated in the direction of the arrow. There are different types of bourdon tubes namely type-c, helix, spiral these are all used in the ways of measuring pressure (depends on the surrounding pressure we use bourdon tubes).

F = k*sqrt [p1-p2]

C – Type bourdon tubes:

Pressure Transmitter:

Produce a linear output proportional to input pressure.

Zero Scale: 3 psi or 4ma.

Full Scale: 15psi or 20 ma.

Most pressure transmitters are built around the pressure capsule concept.

They are usually capable of measuring differential pressure (that is, the Difference between a

high pressure input and a low pressure input) and therefore, are usually called DP transmitters

or DP cells.

A differential pressure capsule is mounted inside a housing. One end of a force bar is connected to the capsule assembly so that the motion of the capsule can be

transmitted to outside the housing. A sealing mechanism is used where the force bar penetrates the housing and also acts as the pivot point for the force bar. Provision is made in

the housing for high- pressure fluid to be applied on one side of the capsule and low-pressure

fluid on the other. Any difference in pressure will cause the capsule to deflect and create motion in the force bar. The top end of the force bar is then connected to a position detector,

which via an electronic system will produce a 4 - 20 ma signal that is proportional to the force bar movement.

ROTAMETERS:

Rotameter is used to monitor maximum and minimum flow rate of the flow meter.

It is a device that measures the rate of flow of (liquid or gas) in a closed tube. It belongs to a class of meters called variable area meters, which measures flow

rate by allowing the cross-sectional area the fluid travel and through to vary, causing a measurable effect.

Rotameter are classified as variable orifice meters.

While fixing it should be vertical due to gravitational force act on the float.

Types of Rotameter:

There are two types of Rotameter they are namely

1. Metal tube

2. Glass tube

Orifice Plate:

The orifice plate is the most common form of restriction that is used in flow measurement. An orifice plate is basically a thin metal plate with a hole bored in the center or

depends on the types of orifice plates holes are bored in the plate. It has a tab on one side where the specification of the plate is stamped. The upstream side of the orifice plate usually has a sharp.

Fixing procedures:

Mostly for gas line diameter weep hole are placed upwards and for oil lines the weep holes are placed downwards while fixing orifice plates due to venting.

Types of orifice plates:

1- Concentric

2- Segmental

3- Quadrant

4- Eccentric

Concentric:

The concentric orifice plate is used for ideal liquid as well as gases and steam service. This orifice

plate beta ratio fall between of 0.15 to 0.75 for liquids and 0.20 to 0.70 for gases, and steam. Best

results occur between value of 0.4 and 0.6. Beta ratio means ratio of the orifice bore to the internal

pipe diameters.

Segmental:

The segmental orifice place has the hole in the form segment of a circle. This is used for colloidal and

slurry flow measurement. For best accuracy, the tap location should be 180º from the center of

tangency.

Quadrant Edge:

It common use in Europe and are particularly useful for pipe sizes less than 2 inch’s.

Quadrant edge orifices produce a relatively constant coefficient of discharge for services with low Reynolds numbers in the range from 100,000 down to

5,000.

Eccentric:

The eccentric orifice plate has a hole eccentric. Use full for measuring containing solids, oil

containing water and wet steam. Eccentric plates can use either flange or vena contract taps, but the

tap must be at 180º or 90º to the eccentric opening.

MASS FLOW METER:

A mass flow meter, also known as an inertial flow meter is a device that measures

mass flow rate of a fluid traveling through a tube. The mass flow rate is the mass of the fluid

traveling past a fixed point per unit time

Mass flow meter works under Coriolis principle.

There are two basic configurations of Coriolis flow meter: the curved tube flow meter and the straight tube flow meter.

The mass flow meter does not measure the volume per unit time (e.g., cubic meters per second) passing through the device; it measures the mass per unit time (e.g., kilograms per second) flowing through the device. Volumetric flow rate is the mass flow rate

divided by the fluid density. If the density is constant, then the relationship is simple. If the fluid has varying density, then the relationship is not simple. The density of the fluid may

change with temperature, pressure, or composition, for example. The fluid may also be a combination of phases such as a fluid with entrained bubbles. Actual density can be determined due to dependency of sound velocity on the controlled liquid concentration.

THERMOCOUPLES:

Thermocouple means name itself says that thermo means thermal or temperature

and couple means pair join together as thermocouple. It is also called as seebeck effect because of the person seebeck who invented it. It is also called as thermo electric effect

A thermocouple consists of two pieces of dissimilar metals with their ends Joined together (by twisting, soldering or welding). When heat is applied to

the junction, a voltage, in the range of milli-volts (mV), is generated. A Thermocouple is therefore said to be self-powered or active transducer.

To convert the emf generated by a thermocouple to the standard 4-20 mA

Signal, a transmitter is needed. This kind of transmitter is called a Temperature transmitter.

There are different types of thermocouple material’s like (K, T, R, J, S, E, V, N, B)

types are used depends on the range of input temperatures it can be choose.

TYPES OF THERMOCOUPLES FOR DIFFERENT TEMPERATURE RANGES:-

Using this above thermocouple chart we can cross check the

thermocouple but for accurate measurement of thermocouple we need to

compensate the room temperature which is acting on the thermocouple that’s the

reason for using diode in the controller’s to compensate room temperature.

Or we can also use ice box techniques near cold junction of

thermocouple for compensation.

RTD:

Resistance Temperature Detectors (RTDs) are temperature sensors that

contain a resistor that changes resistance value as its temperature changes. They have been used for many years to measure temperature in laboratory and industrial processes, and have developed a reputation for accuracy,

repeatability, and stability.

There are three wire and four wire rtd’s depends on the length and for more accuracy they are used.

Thermowell:

The process environment where temperature monitoring is required is often not only hot, but also pressurized and possibly chemically corrosive or radioactive. To

facilitate removal of the temperature sensors (RTD and TC), for examination or replacement and to provide mechanical protection, the sensors are usually mounted inside thermal wells.

The most common types of thermowell

Thermowells are commonly classified according to their connection to a process. The most common types of Thermowells are (1) threaded, (2) socket weld, (3) weld-

in, and (4) flanged.

Level:

The distance between one points to another point is called level.

The units of measurement are either in inch, cm3, meter, etc.

Measuring Instrument:

Level gauge class, DP type transmitter, Displacer transmitter, vibrating fork type

switch, etc.

Many industrial processes require the accurate measurement of fluid or solid

(powder, granule, etc.) height within a vessel. Some process vessels hold a stratified combination of fluids, naturally separated into different layers by virtue of differing densities, where the height of the interface point between liquid layers is of interest.

GAUGE GLASSES:

The principle of a gauge glass is that a liquid will tend to seek a

common level as in ‘U’ tube. They are only used for local indication and their reliability is very important in crosschecking the secondary level instruments. The level gauge or sight

glass is to liquid level measurement as manometers are to pressure measurement: a very simple and effective technology for direct visual indication of process level. In its simplest form, a level gauge is nothing more than a clear tube through which process liquid may be

seen. The following photograph shows a simple example of a sight glass.

Differential Pressure method:

Most pressure transmitters are built around the pressure capsule

concept. They are usually capable of measuring differential pressure (that is, the Difference

between a high pressure input and a low pressure input) and therefore, are usually called DP

transmitters or DP cells.

HP is connected to bottom of the tank and LP is connected to top of the closed tank (if open tank LP is connected to vent area).That HP side acting pressure equal to height

of the tank and density of the liquid. LP side acting vapour pressure.

DP =HP-LP

Displacement type level transmitter:

This works under ARCHIMEDE’S Principle which is (buoyancy force).

The variation in buoyancy resulting from changes liquid level, varies the net

weight of the displacer, increasing or decreasing the load of the torque arm.

The changes is directly proportional to the change in the liquid level.

These level transmitters have major portions of mechanical and pneumatic parts

those are affected by the ambient temperature and pressure.

LVDT:

LVDT is an acronym for Linear Variable Displacement Transducer

LVDT works under the principle of mutual induction, and the displacement

which is a non-electrical energy is converted into an electrical energy.

Turbine Flow meter:

It consist of a turbine (usually four-bladed) placed in the direction of flow.

Within a specified range (flow range usually about 10:1 turndown) the speed of

rotation is directly proportional to flow velocity.

Turbine blades are constructed of ferromagnetic material a pass beneath a magnetic

detector operating as a variable reluctance transducer which produces output voltage

approximately to sin wave of the form.

E = Aw SIN NWT.

Where,

A – constant

W – Angular velocity (proportional to flow velocity)

N – Number of blades

Ultrasonic flow meter:

Ultrasonic flow meter uses Doppler Effect.

Ultrasonic flow meter are ideal for waste water application or any direct

liquid which is conductive or water based;

It will not work with distilled water, also ideal for applications where low

drop, chemical compatibility.

Ultrasonic need only particularities or bubbles in the flow.

Doppler Effect:

It is the change in frequency of a wave for an observer moving relative to its

source.

It is also used for speed measurement in radar speed traps

Doppler flow meter:

Doppler flow meter injects (high frequency typically 100 kilo hertz) sound waves

into moving fluid’s small part of this sound wave is reflected off solid matter, vapor and air

bubbles or eddies / vortices back to a receiver mounted alongside the transmitter.

As it passes through the fluid, the frequency is subject to two changes (one

travelling to upstream against the flow and another one downstream with the flow).

Received frequency:

Doppler flow meter is linear and can be installed without breaking pipes.

FR = FT {(VT + VCOSð) / (VT – VCOSð)}

Hot wire Anemometer:

A Hot wire is inserted in the fluid and maintain at constant temperature

by self-balancing the bridge.

If the flow increases say, more heat is removed, the temperature of the

wire falls and its resistance falls.

This unbalance the bridge, which is detected and the bridge voltage is

increased until the temperature of the wire is restored.

With a constant wire temperature, the heat dissipated by the wire is

equal to the power loss.

I^2 R = A+B SQRT (V)

OR

V = K (I^R – A) ^R

Where k is a constant.

The current I is measured or converted to a voltage by the lower resistor in the bridge)

from which the flow velocity can be delivered, obviously relationship is non-linear and

compensation for changes in fluid temperature is required.

Flow in open channel:

Flow meter in open channels are in supplying and installing radar flow meters for

over 14 years, many of these meters are installed in drains and severs and have never serviced

or even visited after installation and they are still operating perfectly.

Radar will be mounted above the water surface and measure the

flow velocity using RADAR (Radio Detection & Ranging) technology and flow depth using

a level sensor which can be ultrasonic, radar.

The flow rate can be calculated by:

Q = V * A, Accuracy +/- 5%.

Bernoulli’s equation:

Bernoulli’s is used to balance between pressure, velocity and elevation.

Equation:

P+1/2(Þv^2) + þgh = constant

Where,

P – Pressure

Þ – Density

V – Velocity

H – Elevation

G – Gravitational acceleration

State that for an invisid flow of a non – conducting fluid, an

increase in the speed of the fluid occurs simultaneously with a decrease in pressure.

(Increase in velocity then decrease in pressure).

Nucleonic Type Level Transmitter:

NT.L.T operates according to radio-metric principle, utilizing the

physical law that gamma radiation is attenuated as it passes through matter.

Since the source type and the absorption path are constant in this

case, the measure is only affected by the presence of the medium.

All other physical properties such as pressure, temperature, viscosity

and color have no influence.as a consequence, the radiometric measuring method features a

very high level of operational safety and requires partially no maintenance, even under

difficult operating and ambient conditions.

Types of valves:

1. Ball valve

2. Gate valve

3. Global valve

4. Needle valve

5. Mixing valve

6. Diverting valve

7. Butterfly valve

Types of final control elements used in the process industry and their applications:

A control valve essentially comprises of a valve body and an actuator.

Control valve:

A control valve is defined as a power operated device, which modifies the fluid

flow rate in a process control system. It consists of a valve body connected to an actuator

mechanism that is capable of changing the position of a flow-controlling element in the

valve in response to a signal from the controlling system.

Valve body:

A valve body is a device used for the control of fluid flow. It consists of a fluid

retaining assembly; one or more ports between the end opening and a movable closure

member which opens, restricts or closes the port(s).

Actuator:

An actuator is a fluid powered or electrically powered device, which supplies

force and motion to a valve closure member.

Five types of valves:

1. Single seated (ported) globe valve. 2. Double seated (ported) globe valve.

3. Cage type globe valve.

4. Angle valve. 5. Three way globe valves

PROCESS CONTROL

Process control refers to the methods that are used to control process variables when manufacturing a product. For example, factors such as the proportion of one

ingredient to another, the temperature of the materials, how well the ingredients are mixed, and the pressure under which the materials are held can significantly impact the quality of an

end product. Manufacturers control the production process for three reasons:

Reduce variability

Increase efficiency

Ensure safety

CONTROL LOOP

OPEN LOOP:

If in a physical system there no automatic correction of the variation in its output it is called open loop control system. There is no direct measurement of the controlled variable; its basic is in making an accurate estimate of the form or quantity of action

necessary to accomplish a desired objective.

EXAMPLE: Gas is fed from source to vessel through a valve which is controlled by adjusting the actuator load pressure (PL)

In order for control system to work, input pressure and flow rate must be maintained as constant, along with the actuator load pressure. This is because the vessel pressure is not being measured there is no FEEDBACK.

CLOSED LOOP:

If in a physical system there automatic correction of the variation in its output it is called closed loop. In general output can be controlled by input through feedback parameters.

PL

GAS

SOURCE

PROCESS

VESSEL

NATURE OF JOB:

To assist in improvement projects done in and around the plant.

Quench temperature relocated due to functioning abnormally.

Dipping plant temperature monitoring and controlling.

Polymerization plant fixing the DP switch in furnace oil burner (FOB).

Spinning godet temperate feedback loss monitored and swapped the RTD sensor.

Mtp plant to replace faulty counter with serviced one.

In BR & D we used to check temperature and we have a library we used to take some

instrument related notes.

DT we used to check heating plates with temperature indicator and probe’s.

If there are temperature diversion below or above set point we do surface correction from

that DT.

While loading and unloading nitrogen gas in plant we helped technicians.

In biomass we went to service transreciever and changing temperature sensors and

solenoid valves during shutdown.

To gain knowledge about process and interlocks related to process instrumentation and

to apply the same.

To assist in maintenance and troubleshooting activities in day to day basis.

To gain knowledge and help in ISO documentation.

To gain knowledge in TQM activities and apply it in daily work.

To assist in the completion of Preventive Maintenance schedule from Annual Plan on a

monthly basis, and updating Daily Maintenance reports, History cards etc.

To perform daily activities those have been assigned to us.

Process Output

Input

Feed back

ELECTRO

NINCS

INSTRU

MENTS

1ELECTRONIC COUNTER

(LENGTH COUNTER)YES MTP 55 NOV/FEB ARUN.S(TRAINEE) 82,000

2

VIBRATING FORK LEVEL

SWITCH BOARD (HIGH &

LOW) BOARD'S

YES POLYMERIZATION 15 DEC/FEB ARUN.S(TRAINEE) 22,500

3 SELECT COUNTER YES LOOM 2 MAY ARUN.S(TRAINEE) 4000

4 CONTROLLER YEW UT-350 YES NITROGEN PLANT 1 APRIL ARUN.S(TRAINEE) 20,000

5 FEQUENCY COUNTER YES LOOM 2 JUNE ARUN.S(TRAINEE) 5,000

6 LOAD CELL TESTER YES ASM 1 MAY ARUN.S(TRAINEE) 7,000

7 (DM - 97) MULTIMETER YES INSTRUMENT 2 MAY/JUNE ARUN.S(TRAINEE) 2,000

8DATA LOG - POWER SUPPLY

CARDYES LOOM 9 APRIL/MAY ARUN.S(TRAINEE) 13,500

9 RADIX UNIRAD INDICATOR YES DT 1 JUNE ARUN.S(TRAINEE) 2000

10 EWS 15 -9 CARD YES LOOM 1 APRIL ARUN.S(TRAINEE) 5,000

11

HFT - 70 (DIGITAL SURFACE

TEMPERATURE) ANDRITSU

MAKE

YES DT 1 JUNE ARUN.S(TRAINEE) 65,000

12 ELECTRONIC RPM COUNTER YES LOOM 1 FEBRUARY ARUN.S(TRAINEE) 5,000

13305 THERMOMETER

INDICATOR YES DT 2 JUNE ARUN.S(TRAINEE) 15,000

14DIGITAL THERMOMETER

KOMARK MAKEYES DT 1 JUNE ARUN.S(TRAINEE) 40,000

15 ASM WEIGHING INDICATOR YES SPINNING 2 NOVEMBER ARUN.S(TRAINEE) 40,000

16 LOAD CELL INDICATOR YES POLYMERIZATION 1 FEBRUARY ARUN.S(TRAINEE) 15,000

17 PCB BOARDS YES MTP 20 MAY/JUNE ARUN.S(TRAINEE) 16,000

18 POWER SUPPLY CARD YES DT 2 MAY ARUN.S(TRAINEE) 1,500

19 HOOTER YES DIPPING 1 FEBRUARY ARUN.S(TRAINEE) 5,000

20 AT-CONTROL MODULE YES LOOM 1 AUGUST ARUN.S(TRAINEE) 20,000

21 CA-71 YESMASTER

INSTRUMENT1 AUGUST ARUN.S(TRAINEE) 20,000

22 ANEMOMETER YES NITROGEN PLANT 2 DEC/JULY ARUN.S(TRAINEE) 15,000

23 DP PRESSURE SWITCH YES POLYMERIZATION 1 JAN/FEB ARUN.S(TRAINEE) 10,000

24ACTUATOR SV ("2/3" &

"5/3")YES NITOGEN PLANT 1 JANUARY ARUN.S(TRAINEE) 7,000

25 DUAL PLUNGER SOV YES NAUTAMIXER 2 APRIL ARUN.S(TRAINEE) 10,000

26 GAS PRESSURE SWITCH YES BIOGAS 1 MARCH ARUN.S(TRAINEE) 3,500

27 LIMIT SWITCH YES DIPPING 2 FEBRUARY ARUN.S(TRAINEE)

28 PRESSURE SWITCH YES SPINNING 5 JAN/FEB ARUN.S(TRAINEE) 5,000

29PADDLE TYPE LEVEL SWITCH

YES POLYMERIZATION 1 FEBRUARY ARUN.S(TRAINEE) 2,000

30 AIR REGULATORS YES LOOM 9 JAN/MARCH ARUN.S(TRAINEE) 15,000

31 ROTAMETER YES POLYMERIZATION 1 APRIL ARUN.S(TRAINEE) 2,000

32 TEMPERATURE PROBE YES DT 4 JUNE ARUN.S(TRAINEE) 4,000

33 MODULATION MOTOR YES DIPPING 2 DEC/JAN ARUN.S(TRAINEE) 2,00,000

34 SPARK PLUG YES DIPPING 8 DEC/APRIL ARUN.S(TRAINEE) 40,000

37 SOLENOID VALVE YES DEPARTEMENT 8 JAN/MAY ARUN.S(TRAINEE) 15,000

38 LY-25/16 GAS FLOW METER YES LPG BULLET AREA 1 FEBRUARY ARUN.S(TRAINEE) 5,000

39 PRESSURE GUAGE YES PSA TOWER 2 JUNE ARUN.S(TRAINEE)

40FEEDBACK PRV

YESOLD POLY ('0'-

MTR)1 JUNE ARUN.S(TRAINEE) 5,000

41 AIR REGULATORS YES POLYMERIZATION 2 MAY ARUN.S(TRAINEE) 2,000

PRICE

INSTRUMENTS SERVICES IN INSTRUMENTATION DEPARTEMENT UNDER MR.VIVEK SINGH SEGAR PERMISSION

MATERIAL DESCRIPTIONS.NOTYPE

AREA QUANTITY MONTH SERVICED PERSON

From this above list I saved around 739200 RUPEES only during my

graduate act apprentice period apart from my instrumentation and maintenance work and I am

really thankful for our instrument team members who supported and guided me to do this

wonderful act.

PROJECT INVOLVED

Calibration bench set up wiring connections and pneumatic connections are

made in our department as per the instruments requirement.

Biomass automatic bunker conveyer stops using vibrating fork type level

Switch.

To avoid draw twister heater box surface temperature losing using ANABOND

non insulating conductivity paste.

Draw twister new temperature control system using delta-v temperature

controller.

Repairing and servicing electronic and instrument components

CONCLUSION:

In the course of training at SRF Limited- TTBM, I had learnt a lot about this

organization and also about the latest on goings and development in Instrumenta t ion

field. I express my sincere thanks to all the members who have helped directly and

indirectly. Without their help and guidance I wouldn’t have been able to successfully

complete my training worth fully.