UNIT 2 PROCESSES AND PROCEDURES

UNIT 2

PROCESSES AND PROCEDURES

General Objectives

1. To read and understand description of processes and procedures.
2. To participate confidently actively in oral exchanges of a longer duration on the

    description of processes.

Specific Objectives

By the end of this unit, you will be able to :

1. label accurately the sequence of processes and procedures
2. translate the sequence of processes from textual to non-textual form
3. identify the appropriate meaning and pronunciation of  semi-technical words from the dictionary
4. choose appropriate verbs to describe a process
5. identify the structure of passive sentences
6. write a description of a process using the passive form
7. identify the different uses of  preposition of place, in particular : in, into ,onto, to
8. complete paragraphs using the correct passive forms
9. present orally  a description of a process to a small audience.
   
    
   
   INPUT 

Your lecturer is going to show a few objects such as ping pong balls, disposable cutlery and garbage bags.

1. Do you know what these objects are made of ?
2. How is the material used in these objects being produced ?

ACTIVITY 1

You are going to listen to a lecturer explaining how celluloid is processed. As you listen, number the following pictures according to  the sequence as mentioned by the lecturer in the tape.

	1

(Adapted from “How Things Work 1” p 365)

ACTIVITY 2

Read the following ttext on how acetate is processed. Then answer the questions that follow.    

THE ACETATE PROCESS

*

Acetate was the first thermoplastic or heat sensitive fibre. It is widely used in satins, brocades and taffeta.  The basic ingredients used are wood pulp or cotton linters, acetic acid, acetic anhydride and sulphuric acid.     Firstly, the wood pulp or cotton linters are processed to obtain purified cellulose.  Then, the cellulose is mixed with acetic acid, acetic anhydride and sulphuric acid as a catalyst. Next, the mixture is aged for 20 hours. This stage is called the acetylation process.  The product of this process is a semi-solid substance.  This substance will then go through the precipitation process. In this process the solid particles are separated from the liquid. These particles are the acid-resin flakes.     After that, the flakes are dissolved in acetone. The solution is subsequently filtered before it is sent to the spinning pump. Here, the solution is pumped through the spinneret. It later emerges in strands which are dried by air blown across them.  Finally, the strands are stretched and wound onto beams, cones and bobbins. They are now ready for use. (Adapted from “Textiles” p90)

(Diagram taken  from “How Things Work 1”p373)

1. Use your dictionary to find the meaning and pronunciation of the following

     words.

	Pronunciation	Meaning
Example :     Static	/ѕtætɪk /	Not  moving or changing
i)   acetate
ii)  substance
iii) thermoplastic
iv) purified
v)  fibre
vi) catalyst
vii) aged
viii) precipitation
ix) particles
x) solution

2. Refer to the text on how acetate is processed and decide whether the following statements are True(T) or False(F).

1. One of the basic ingredients for making acetate is wood pulp.	(           )
2. In the acetylation process, the mixture is aged for 2 days.	(           )
3. Acetate was the first heat sensitive fabric produced.	(           )
4. The acid resin flakes are later dissolved in acetone and filtered.	(           )
5. In the final process, the strands are cut to desired lengths.	(           )

ACTIVITY 3

Read the following text.  

MANUFACTURE OF MICROCHIPS A microchip is a small electronic component which contains an integrated circuit on one piece of silicon. Silicon chips, also called integrated circuits are the building blocks of modern electronics.  There are many types of chips, each with a different function.  The process of manufacturing microchips starts with silicon rods.  The diameter of a silicon rod is about 10-15 cm in diameter. First of all, these rods are cut into thin slices called wafers.  The faces of the wafers are then polished.  Next, the faces are covered with a material called photoresist.  Photoresist is a kind of plastic which is sensitive to light.  The faces of the wafer are coated with photoresist before entering the photographic part of the process.  Then, at the next stage, the wafer is exposed to the image from a mask plate.  The image is really a printed diagram of the circuit.  Once the image is on the wafer, it is developed photographically.  This means the exposed photoresist hardens and the unexposed photoresist is removed.  Next, we come to an important part of the photoresist process.  Having removed the unexposed photoresist, chemicals are applied to process the wafer through the photoresist image. In the final part, the photoresist is removed and the process starts all over again.  The entire process is repeated many times for other images to be printed on before the wafers are sent for testing and mounting.  The wafers that failed the testing will be rejected.

                                      (Adapted from “How Things Work 1”, p 375)

ACTIVITY 3

Answer the following questions based on the above text about The Manufacture of Microchips.

1.What is another name for silicon chips ?

  ________________________________

2. What are the slices of silicon called ?

  ______________________________

3. Are all silicon chips the same ?

   _____________________________

4. When can the faces of the wafer be coated with photoresist ?

    ________________________________________________

5.When can the chemicals be applied to the wafer?

   ______________________________________

6.Can all the wafers be used after the entire process ?

   ________________________________________

ACTIVITY 4

Read and underline the sequence markers in the passage above to help you identify the different stages of the manufacturing process of microchips. Then fill in the diagram below with the correct procedure.

The faces of the wafers are exposed to make the image on mask plate
Silicones are cut into wafers and polished




The unexposed photoresist is removed






The photoresist is removed

LANGUAGE FOCUS 1

Lexical Items

It is important to use suitable verbs to describe a certain process accurately.

  

To make porcelain, firstly, quartz and felspar are ground through a coarse mill and later through a ball mill to produce a fine powder.  The powder is mixed with kaolin and water in a mixing drum. Next, the mixture is filtered through a huge sieve. …….

 

(Adapted from “How Things Work 1”p349)

ACTIVITY 5

Match the pictures with the correct verbs given.    



    lowered          packed            turned                rotated           transported     
    discarded       weighed          dipped               heated            controlled
    cut                 dropped           carried               raised             painted

1. _______________	2. ______________	3. _____________	4. _____________
5. _______________	6. _______________	7._____________	8._____________
9.  _______________	10. ______________	11. ____________	12. ____________

ACTIVITY 6

Read the text on how acetate is made (refer to page 3) and complete Table 1. You can put more than one word in each box.
    1            2            3            4

Firstly		are processed
	the cellulose		with acetic acid, acetic anhydride and sulphuric acid
Next		is aged
	the flakes		in acetone
Finally		are stretched and wound

                                                           Table 1

What do you call the category of words in Column 1, 2 and 3 ? Discuss with your friends. Take note of the structure of the sentences in Table 1.

LANGUAGE FOCUS 2

Passive Voice

In general, passive  sentences are formed by placing the object of the sentences in front of the passive verb.

We often need to describe processes in technical writing. To describe a process, the verbs used are usually in the passive form. This is because we are more interested in the action (process) rather than the agent (person). As the process involved can be carried out anywhere at any time, the present passive is often used.

The present passive verb is written like this :-

is	verb  +     ed  (singular)	eg:   is mixed
	Irregular past participle	is wound

 

are	verb   +    ed   (plural)	eg:   are added
	Irregular past participle	are frozen

ACTIVITY 7

A. Fill in the blanks with  either “is” or “are”.

eg:   The screwdriver is kept in the tool box.

1. The furniture   ______         painted  with a special varnish.
2. The molten metal _________  forced into the dies.
3. The two solutions  _________  mixed in the heatproof beaker.
4. A hole  _______ drilled into the wall.
5.  Two shovelfuls of sand _____ put into a wheelbarrow.



B.  The paragraph below is about the process of making rayon. Fill in the blanks with the
     correct passive forms.

        Firstly, blotterlike sheets of purified  cellulose  (1)_________ (treat) with caustic soda. Next, excess liquid (2)__________(press) out of the sheets using rollers. After that, the remaining sheets (3)_________(crumble) in a shredder, turning them into alkali crumbs. Then, the crumbs (4)_________(age)  for 50 hours. Later on, the  crumbs (5)______(treat) with carbon disulphide to form cellulose xantate. After  that, they (6)_____(mix) with caustic soda to form a viscose solution. The solution (7)______(age) for 4-5 days and then filtered. Next, the solution (8)_______(pump) to a spinneret and extruded into a sulphuric acid bath. Here, the solution (9)_______(decompose ) into cellulose in the form of filaments emerging form the nozzle. These are then passed through various cleaning, bleaching, hardening and refining baths. After drying, 10-20 filaments (10)________  (spin) together to form the rayon yarn.

ACTIVITY 8

Change these sentences into the passive form.

E.g.    Pour the sulphuric acid into the beaker.     The sulphuric acid is poured into the beaker. Mix the powder with kaolin and water. _____________________________________ Filter the mixture through a sieve. _____________________________________ Dissolve the flakes in acetone. _____________________________________ Process the wood pulp to purify it. _____________________________________ Separate the solids from the liquid. _____________________________________ Cover the food with a plastic film. _____________________________________ Connect the cable to the printer. _____________________________________ Apply varnish to the wooden frame. _____________________________________ Cut  the silicon rods into thin slices. _____________________________________ 10.Repeat the process many times.     _____________________________________

LANGUAGE FOCUS 3

Prepositions

Prepositions are words which are used to show the way in which other words are connected.

One category of preposition is the preposition of place. In this unit you have come across prepositions like in, to, into and onto. These prepositions are used to locate a stage in a process.

    E.g. The acid-resin flakes are dissolved in acetone.

           The solution is decomposed into cellulose.

           The computer is connected to the printer.

           The strands are stretched and wound onto bobbins, beams and cones ready for use.

                                                                   

                                                                             onto

                                                                                                      


                     into   
                                                                              onto

in

                                                                         inin
                        
                                     to

ACTIVITY 9

Fill in the blanks with in, into, to and onto .

1. Water turns _______ vapour when it reaches boiling point.

2. Air and fuel are mixed _____ the combustion chamber.

3. The semi-dry pulp is sent ____ the dryer for drying.

4. The equipment was loaded _____ a truck.

5. The glazed porcelain is baked ___ a hot oven.

6. Iron is extracted from its ore ___ a blast furnace.

7. The cold vapour is sucked back ____ the compressor.

8. Signals are transmitted by cable ___ the international telephone exchange.

9. A forklift is used to move heavy boxes ____ the lorries.

10. Mix the chemicals ____ a beaker.

                                         

Imagine you are the Supervisor of an automotive factory.  A group

of students are going to visit your company.  Your Superior has

asked you to prepare a description on how car is assembled.

Two of your colleagues are going to help you.  Find materials for

this topic and write out the description with the help of flow charts

and pictures.  Then present your findings to the students.

  ANSWER KEY

Activity 1

	1
2	6	3

Activity  2

A. Meaning and pronunciation.

word	pronunciation	meaning
1.acetate	/ æsitеɪt /	Smooth man-made cloth, sometimes used for making clothes
2.substance	/ ѕʌbѕtǝns /	A solid, powder or liquid with particular properties.
3.thermoplastic	/ɵɜ:mǝʊplæstɪk /	A plastic which becomes soft when it is heated and hard when it cools down
4.purified	/  pjʊǝrɪfaid  /	Make a substance pure by removing any harmful or dirty or inferior substance
5.fibre	/  faibǝ /	A type of cloth or any other material that is made from or consists of threads
6.catalyst	/ kætǝlɪst /	A substance that speeds up the rate of a chemical reaction without itself changing or being affected in any way.
7.aged	/ еɪʤd /	The process of becoming physically or mentally older
8.precipitation	/  prɪsɪpɪtеɪʃn   /	A process in a chemical reaction which causes solid particles to become separated from a liquid
9.particles	/ pa:tɪkǝls  /	A very small piece or amount of a substance.
10.solution	/ sǝlu: ʃǝn /	A liquid in which a solid substance or gas has been dissolved.

1. True/False

1. T
2. F
3. T
4. T
5. F

Activity 3

Faces of wafer are coated with photoresist

The faces of the wafers are exposed to make the image on mask plate
Silicones are cut into wafers and polished




The unexposed photoresist is removed

Chemicals are applied to process the wafer.





The entire process is repeated many times for other images.
The photoresist is removed






The wafers are sent for testing and mounting.

Activity 4

1. Integrated circuits
2. Wafers
3. No, they are not.
4. After they have been polished.
5. After removing the unexposed photoresist.
6. No, those which failed the testing will be discarded

Activity 5

heated dipped rotated controlled discarded 6.   transported

dropped weighed lowered carried packed 12. painted

Activity 6

    1            2            3            4

Firstly	the wood pulp or cotton linters	are processed	to obtain purified cellulose.
Then	the cellulose	is mixed	with acetic acid, acetic anhydride and sulphuric acid.
Next	the mixture	is aged	for 20 hours
After that	the flakes	are dissolved	in acetone
Finally	the strands	are stretched and wound	onto beams or cones or bobbins

Column 1 : Sequence Connectors

Column 2 : Subject

Column 3 : Passive verb

Activity 7

A.   1. is            2. is        3. are        4. is         5. are

B.

1.  are treated        is pressed 3.  are crumbled 4.  are aged 5.  are treated 6.  are mixed 7.  is aged   8.  is pumped 9.  is decomposed 10. are spun

Activity 8

1. The powder is mixed with kaolin and water
2. The mixture is filtered through a sieve
3. The flakes are dissolved in acetone
4. The wood pulp is processed to purify it
5. The solids are separated from the liquid.
6. The food is covered with a plastic film.
7. The cable is connected to the printer
8. Varnish is applied to the wooden frame.
9. The silicon rods are cut into thin slices.
10. The process is repeated many times.

Activity 9

1. into
2. in
3. to
4. onto
5. in
6. in
7. into
8. to
9. onto
10. in

SELF- ASSESSMENT

Self-assessment 1

Fill in the blanks with the suitable passive form of the verb given in the brackets as well as suitable prepositions. Use the diagram below to complete this exercise.

    The  jack  is placed (place) under the car. The lever at the side of the jack ______(push) _______ and ________. This movement _______ (change) _______ a

reacting motion which then glides the piston forward and backward.

    Each movement of the piston pumps a small amount of fluid. Next, the fluid ____ (pump) from the reservoir_______ the one-way valve  ______ the main cylinder. As a result of this action, the jack  ______ (raise). Thus the car _____ (lift) ______ the ground.

    To lower the car, the one-way valve ______(release). This action allows the weight of the car to force the fluid ________ the cylinder back ______ the reservoir. The car slowly moves downwards.

                                                                      PISTON               VALVE

SCORE

16

Self-assessment 2

Write out sentences based on the pictures below. The first one has been done for you.

1.	The iron rod is heated over the fire.
2.
3.
4.
5.

SCORE

4

Self-assessment 3    

The sentences below show the process of water purification. They are not in the correct sequence. Rearrange and rewrite them into a paragraph. Link up the sentences with sequence connectors such as “ then”, “first”, “finally” (where necessary).

   

   

• The water is finally piped to homes, schools and factories.

• Certain chemicals are added into the water.

• Rainwater is first collected in an open reservoir.

• The purified water is stored in an enclosed reservoir.

• The clumps of dirt cling onto the bed of sand and gravel.

• Chlorine gas is passed into the water to kill germs.

• It is pumped to a building to undergo the purification process.

WATER PURIFICATION PROCESS

SCORE     12

Self-assessment 4

Listen to the tape (Tapescript in Appendix 2.1). With reference to the pictures in Activity 1 (on page 2), fill in the blanks with suitable sequence connectors in the text below.  Then, complete the flow chart to indicate the process.  

In the ________stage of the process, the cotton is mixed with concentrated nitric acid and sulphuric acid, forming nitrocellulose.  _________ the dried nitrocellulose is stored at a temperature of between 15 and 20 C for 24 hours.  It is __________washed with water and dried.  __________camphor and alcohol are added and the mixture is turned into a stiff paste.  _____________there are two ways in which the celluloid can be treated.  It can be rolled into plates and stored for further processing or it can be shredded into small pieces.  __________, the celluloid is moulded into different shapes and sizes while hot.

Cotton is mixed with concentrated nitric acid and sulphuric acid to form nitrocellulose

SCORE

15

Self-assessment 5

Fill in the blanks with the appropriate passive form from the verbs given in the brackets.

1. Tub type washing machine _____________ (provide) with a draining pump.
2. The coils ____________ (connect) to each other and to a battery through an on/off switch.
3. When the switch ____________ (open), a spring pulls the armature away from the magnet.
4. The water ______________ (heat) in the boiler and becomes steam.
5. During the smelting process, a mixture of copper and iron sulphides __________ (form).
6. The valves ____________ (close) to prevent the fluid from entering the chamber.
7. Different washing agents ___________ (add) to the fabric to remove the dirt.
8. The handle _________ (turn) clockwise to tighten the screw.

SCORE

8

TOTAL SCORE  :        
                                          55

   ANSWER KEY TO SELF-ASSESSMENT ACTIVITIES

Self-assessment 1

The jack is placed (place) under the car. The lever at the side of the jack is pushed (push) up and down. This movement is changed (change) into a reacting motion which then glides the piston forward and backward.

    Each movement of the piston pumps a small amount of fluid. Next, the fluid is pumped (pump) from the reservoir through the one-way valve into the main cylinder. As a result of this action, the jack is raised (raise). Thus the car is lifted (lift) from the ground.

    To lower the car, the one-way valve is released (release). This action allows the weight of the car to force the fluid from the cylinder back into the reservoir. The car slowly moves downwards.

Self-assessment 2

1. The brush is dipped into the alcohol.
2. The block is weighed on the balance.
3. The ore is transported to the refinery.
4. The car is lowered onto the ground.

Self-assessment 3

WATER PURIFICATION PROCESS

Rainwater is first collected in an open reservoir. After that it is pumped to a building to undergo the purification process. Then certain chemicals are added into the water. Next, the clumps of dirt cling onto the bed of sand and gravel. Following this, chlorine gas is then passed into the water to kill germs. Next, the purified water is stored in an enclosed reservoir. The water is finally piped to homes, schools and factories.

(any other suitable sequence connectors are accepted)

Self-assessment 4

In the first stage of the process, the cotton is mixed with concentrated nitric acid and sulphuric acid, forming nitrocellulose.  Then the dried nitrocellulose is stored at a temperature of between 15 and 20 C for 24 hours.  It is then washed with water and dried.  Next camphor and alcohol are added and the mixture is turned into a stiff paste.  After this there are two ways in which the celluloid can be treated.  It can be rolled into plates and stored for further processing or it can be shredded into small pieces.  Finally, the celluloid is moulded into different shapes and sizes while hot.

This mixture is washed with water and dried.
The nitrocellulose is stored at 15 -20 C for 24 hours
Cotton is mixed with concentrated nitric acid and sulphuric acid to form nitrocellulose





The mixture is stirred into a stiff paste
Camphor and alcohol are added





The plates are stored for further processing
The cellulose is rolled into plates






The cellulose is moulded into different shapes and sizes while it is hot
Cellulose is shredded into small pieces

The cellulose is dried

Self-assessment 5

1. is provided
2. are connected
3. is opened
4. is heated
5. is formed
6. are closed
7. are added
8. is turned

SELF-ASSESSMENT FEEDBACK

SCORE	REMARKS
46 - 55	Well done !  Move on to the next unit.
36 - 45	Good. Be more careful while answering. Please go     through your mistakes.
26 - 35	Pay attention to your weaker areas.
0 - 25	Please go through the unit again or see your lecturer.

APPENDIX 2.1

   TAPESCRIPT For Unit 2 : Processes and Procedures  (Activity 1)

Celluloid is one of the oldest kinds of plastic.  It was first produced in 1869.  It was widely used in the early days of the film industry.  However, nowadays, it is commonly used in the making of objects such as toys, ping-pong balls, brushes, combs, handles and many others.

The basic ingredient used in making celluloid is cotton.  In the first stage of the process, the cotton is mixed with concentrated nitric acid and sulfuric acid, forming nitrocellulose.  Next, the mixture is stored at a temperature of between 15 and 20C for 24 hours.  It is then washed with water and dried.  Subsequently, the dried nitrocellulose is thoroughly kneaded with a solution of camphor in alcohol and is turned into a stiff paste.  After this there are two possible ways in which the celluloid can be treated.  Either the mixture is rolled into plates and stored for further processing or it is shredded into small pieces, dried and finally molded into different shapes and sizes while hot.