Case Study on

Instrumentation System
Prepared by:

 SAURAB BHUSAL (074BCT537)

 SAROJ KUMAR KATWAL (074BCT536)
 SURAJ PANDEY (074BCT545)
 KUNDAN DAHAL (074BCT517)
Objectives

 To visit any of the industrial area.

 To study the existing technology of the factory under supervision
of senior technician.
 Tofind out the defects (if any) in the existing instrumentation
system.
 Tosuggest the instrumentation system to overcome the defect so
that it will be more beneficial and efficient for the existing
system.
Information about organization

 Name : Ganapati Pet Udhyog

 Location : Patan Industrial Area
 Major Work :
Manufacture of plastic jars
CURRENT PROCESS
CONTROL SYSTEM
Injection Molding Process
Raw Material Master batch
-

Mixing

Raw material fed

into the hopper

Material is plasticized Clamp the mould at

in the barrel specified load of tonnage

Inject the molten material into the closed

mould at required speed and pressure

Allow the material to cool

for solidification as desired

Open the mould and

eject the component

Packaging for
secondary process

 
Blowing Process
Preform is preheated

Open the mould and insert the

preform

Blowing of air into preform

Allow the bottle to cool for

solidification as desired shape

Open the mould and eject the

component
Limitations of the existing system

 Mixing of PET and master batch (coloring agent) are done

manually.

 Preform must be passed to another stage for final shape.

Proposed System
PET Master
batch

valve relay valve

8255
micro
contr PPI
olle A
r

motor

mixer

valve relay

Conveyer belt
Components of proposed
system
Relay:

Relay are switches that open or close circuits

electromagnetically. Relays control one electrical circuit by
opening and closing contacts in another circuit. In our case,
it adjust the valve position.
Container Valves:

Large amount of Raw materials i.e. PET and Master-Batch are

contained separately in different containers. Two valves are used for
the flow of these two materials respectively. The surface area of pipe
flowing the PET is larger than that of valve flowing Master-Batch. Our
aim is to flow 100kg and 300gm of PET and Master-Batch in same
time period. Hence, the area for pipe of PET is larger than those of pipe
of Master-Batch.
We have programmed the Microcontroller and PPI in such a way that
after certain time interval (the time in which we achieved the required
amount of PET and Master-batch) , the micro processing unit sends
the signal to relay hence turning it off ant both the valves closes.
 MIXER:

After the definite time interval, the required amount of Raw materials
is collected in the mixing container. Again, the PPI is programmed in
such a way that after the closing of Relay the PPI sends signal to active
the motor. The time duration for running the motor is again
programmed and after certain time the motor stops. The motor properly
mixes the two material(the time during which proper mixed is achieved
is programmed ).
 CONVEYOR BELT:

A Conveyor Belt is the carrying medium of the mixed material up to

the place where the Hopper dryer loads the require amount of mixed
raw material. The mixture is fed into the conveyor system via the
opening of a valve. This valve is guided by a relay switch.
During mixing process, the motor is initiated by the signal given by the
PPI after certain time instant.(The time during where container
achieves require mass of material). The mixing time require to properly
mix up the materials is programmed in the PPI, hence after that certain
time the PPI sends back the signal to stop the motor and
simultaneously it switches on relay
Benefits of proposed system

1. Manpower will be reduced as the system is automated.

2. Diligence, accuracy and convenience is achieved.
3. Accidents will be minimized to a great extent.
4. No variation in quality because weight of raw material to be
added are taken by the weight sensor.
5. Cost of the overall manufacturing process decreases.
Thank You