BK Report and Project

2017
Declaration
I would like to declare that I have successfully completed a four-month internship program at MOHA soft
drinks industry at Hawassa millennium plant. I have stayed from late November 2016 to February 2017 in
this internship program. It is obvious that Debre Tabor University Faculty of technology, Department of
electrical and computer engineering is established sustainable network with private and public sectors to
create better linkage between industrial Companies. During this internship time, I have improved my
theoretical and practical skills.
Here by I state that this final internship report and project has been submitted to Debre Tabor Faculty of
technology, Department of electrical and computer engineering. This paper includes all requirements of
an internship program. And also the signatures signed below declare this report is original and not copied
from any source.
Approval of: - The mentor Mr.Tibebu
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Acknowledgement
Firstly, I would like to express my deepest gratitude and appreciation to my advisor Mr. Tibebu whose
help, suggestions and encouragement helped me to coordinate and conduct this internship project and
report. Secondly my thanks go to my brotherly supervisor Furi Lemesa programmer of the company,
whose best advice and follow up helped me a lot. And also, I would like to say thanks to Debre Tabor
University and specially Department of Electrical and computer engineering for giving me the
opportunity to build up myself in industrial internship program and to have practical knowledge. My last
thanks goes to the MOHA soft drinks factory Hawassa Millennium Pepsi cola plant whose cooperation
and guidance was great.
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Executive summary
Obviously, Internship program is necessarily important for students with their respective departments the
joined. And it gives the trainee student a great opportunity to have some experiences and to correlate the
theoretical knowledge with the practical world. Thanks to Debre Tabor University I got the chance to
have this experience both theoretically and practically. Finally, it gives the chance for the students to
develop their communicating skill and work ethics.
Hawassa millennium Pepsi cola plant is one of the sister companies of MOHA soft drink companies and
produces different items of soft drinks including Pepsi, Mirinda apple, Mirinda orange, Mirinda tonic,
Mirinda pineapple and 7-up. As the company gives the chance for the students to have some practical
knowledge, its great chance for me to experience it and I have gained knowledge, identified a problem,
suggested solution for the problem and some recommendations given to the company are briefly
discussed.
As I have assigned to this company named MOHA soft drink factory Hawassa Millennium Pepsi cola
plant branch according to Debre Tabor University curriculums, I have engaged to stay in the company for
four months starting from late November to end of February. Over these months, I have tried to correlate
my classroom study to the actual world, I have adapted a lot on social interaction with all co-workers of
the company, I have participated in maintenance of the machine and I have identified problem and
discussed on the solutions by using PLC (programmed logic controller) software which is called Simatic
step-7 software and as expected I have achieved what should be achieved from the solution. Oven
temperature controller with cooling fun has been controlled auto-manually.
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Table of Contents
Declaration ..................................................................................................................................................... i
Acknowledgement ........................................................................................................................................ ii
Executive summary ...................................................................................................................................... iii
List of figures ........................................................................................................................................... vii
List of acronyms ..................................................................................................................................... viii
CHAPTER ONE ............................................................................................................................................... 1
INTRODUCTION ......................................................................................................................................... 1
1.1 Background of the Company............................................................................................................... 1
1.1.1 Brief History of Pepsi cola ............................................................................................................ 1
1.1.2 Brief history of Hawassa millennium Pepsi Cola plant................................................................. 2
1.1.3 Main Products of the company .................................................................................................... 2
1.1.4 Main Customers of the company ................................................................................................. 3
1.1.5 Overall organization of Hawassa Millennium Pepsi cola plant .................................................... 3
1.1.6 Overall organization and work flow of the company .................................................................. 4
CHAPTER TWO .............................................................................................................................................. 5
OVERALL INTERNSHIP EXPERIENCE........................................................................................................... 5
2.1 How I get into the company? .............................................................................................................. 5
2.2. The section of the company I have been working in ......................................................................... 5
2.2.1 Power Distribution ....................................................................................................................... 6
2.2.2 Control system ............................................................................................................................. 8
2.3. The work flow of technical and production section ........................................................................ 10
2.4 Description of the plant .................................................................................................................... 11
2.5 Description of the machine listed above .......................................................................................... 12
2.5.1. Case(Crate) Washer Machine ................................................................................................... 12
2.5.2. Packer and un-packer machines ............................................................................................... 12
2.5.3 Bottle washer machine .............................................................................................................. 14
2.5.4 EBI (Empty bottle inspection) .................................................................................................... 16
2.5.4 Mixer machine ........................................................................................................................... 19
2.5.6 Filler Machine............................................................................................................................. 20
2.5.7 Data Coding Machines ............................................................................................................... 22
2.5.8 Case Conveyor and Container Conveyor ................................................................................... 22
2.6 Carbon Dioxide Plant ........................................................................................................................ 23
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2.7 Chiller and Compressor Plant Room ................................................................................................. 24

2.7.1 Chiller or refrigerator ................................................................................................................. 24
2.7.2 Compressor ................................................................................................................................ 24
2.8 Boiler Plant ........................................................................................................................................ 25
2.8.1 Components of boiler ................................................................................................................ 25
2.9 The Work Piece or Tasks I Have Been Executing .............................................................................. 25
2.10 The Procedure I Have Been Using While Performing my Work Tasks ............................................ 26
2.11 How good I have been performing my work tasks ......................................................................... 26
2.12 Challenges faced me while performing my work ........................................................................... 26
2.13 Order to Overcome These Challenges ............................................................................................ 26
CHAPTER THREE .......................................................................................................................................... 27
OVER ALL BENEFITS GAINED FROM INTERNSHIP.................................................................................... 27
3.1 In terms of improving practical skill ................................................................................................ 27
3. 2 In terms of upgrading theoretical knowledge.................................................................................. 28
3.3 In terms of improving inter-personal communication skill .............................................................. 28
3.4 In terms of improving team playing skills ......................................................................................... 28
3.5 In terms of Improving Leadership Skill.............................................................................................. 29
3.6 In terms of Understanding about Work Ethics Related Issues ......................................................... 29
3.7 In terms of Entrepreneurship Skill .................................................................................................... 29
CHAPTER FOUR ........................................................................................................................................... 30
SYSTEM DESIGN AND GENERAL OVERVIEW OF THE PROJECT ................................................................ 30
4.1 Introduction ...................................................................................................................................... 30
4.1.1 Background of the project ......................................................................................................... 30
4.2 Objectives of the project................................................................................................................... 30
4.2.1 General objectives ..................................................................................................................... 30
4.2.2 Specific objectives ...................................................................................................................... 30
4.3 Statement of the problem ................................................................................................................ 31
4.4 Solution suggested ............................................................................................................................ 31
4.5 Methodology of the project .............................................................................................................. 31
4.6 Limitation of this project ................................................................................................................... 31
4.7 Literature review............................................................................................................................... 31
4.7.1 Material Requirement................................................................................................................ 31
4.8 System Design and block diagram .................................................................................................... 33
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4.8.1 Block diagram of the project ...................................................................................................... 33

4.9 Flowchart of the project ................................................................................................................... 34
4.10 Principle of operation ..................................................................................................................... 35
4.10.1 Manually starting method ....................................................................................................... 36
4.9.2 Timer based starting method..................................................................................................... 36
4.9.3 Temperature Sensor based starting method ............................................................................. 38
4.9.4 The cooling fun........................................................................................................................... 39
CHAPTER FIVE ............................................................................................................................................. 40
RESULT AND DISCUSSION ....................................................................................................................... 40
CHAPTER SIX................................................................................................................................................ 44
CONCLUSION AND RECOMMENDATION ................................................................................................ 44
5.1 Conclusion ......................................................................................................................................... 44
5.2 Recommendation.............................................................................................................................. 45
5.2.1 Recommendation to the hosting company ............................................................................... 45
4.2.2 Recommendation to the University ........................................................................................... 45
References .................................................................................................................................................. 46
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List of figures
Figure 1: Overall organization of the company ............................................. Error! Bookmark not defined.
Figure 2: Power distribution of the company................................................. Error! Bookmark not defined.
Figure 3: Wiring diagram of VFD ................................................................................................................ 9
Figure 4: Variable frequency drive system ................................................................................................... 9
Figure 5: Work flow of the section ............................................................................................................. 11
Figure 6: Crate washer machine.................................................................................................................. 12
Figure 7: Un-packer machine...................................................................................................................... 13
Figure 8: Packer machine............................................................................................................................ 13
Figure 9: Bottle washer machine ................................................................................................................ 14
Figure 10: Water flow of bottle washer ...................................................................................................... 15
Figure 11: EBI machine and its components .............................................................................................. 17
Figure 12: Fallen-over container detection ................................................................................................. 18
Figure 13: Detection of broken, fallen over, over filled, and under filled .................................................. 18
Figure 14: Filler and its components.............................................................. Error! Bookmark not defined.
Figure 15: Case conveyor and container ..................................................................................................... 22
Figure 16: Block diagram of the project ..................................................................................................... 34
Figure 17: Flowchart of the project............................................................................................................. 35
Figure 18: Manually starting method .......................................................................................................... 36
Figure 19: Timer based starting method ..................................................................................................... 37
Figure 20: Temperature sensor based starting method ............................................................................... 38
Figure 21: The cooling fun ......................................................................................................................... 39
Figure 22: Simulation of the overall auto-manually starting method ......................................................... 40
Figure 23: Simulation of manual starting method....................................................................................... 41
Figure 24: Simulation of timer based starting method ................................................................................ 41
Figure 25: Simulation of temperature sensor based method ....................................................................... 42
Figure 26: Simulation of the cooling fun .................................................................................................... 43
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List of acronyms
AC....Alternate current
CPUCentral processing unit
DC.Direct current
EBI.........Empty bottle inspection
EEPCo.Ethiopian electric power corporation
LV...Low voltage
MEA...Mono-ethanol amine
PE...Photo electric
PH.power of hydrogen
PLC.programmable logic controller
RLO..Result of logic operation
SR...Set-reset
VFD..Variable frequency drivers
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CHAPTER ONE
INTRODUCTION
Hawassa Millennium Pepsi cola plant is found in the southern region of Ethiopia (SNNPR) and southern
edge of Hawassa city. It is licensed under MOHA soft drinks industry as 7th plant of its sister companies.
In 1999, the foundation of the plant was laid and completed the whole building as well as more advanced
technology machinery erection done and in august 2007, it started production. The plant was inaugurated
on September 03/2007 and started production of its licensed products for its costumers officially. It is
applying very sophisticated machinery and advanced technology. It is producing 36000 bottles per hour
of 300ml soft drinks like Pepsi, Mirinda orange, Mirinda apple, Mirinda tonic, Mirinda pineapple and 7-
up are produced by the plant. Hawassa Pepsi cola has been distributing the products for local costumers
mainly southern part of Ethiopia and some parts of Oromia region.
During the course of production of such products, a series of processes carried out from start to the end
when a product is finally dispatched for consumption. These processes are carried out a series of machine
and there is also utility lines help to prepare an ingredient or product to be consumed in the course of
production of product.
The power distribution of the plant is from its main supply, EEPCo. and its controlling system is also
mainly PLC control system. Finally, the speed of AC motor generally depends on the frequency of the
supply voltage.
1.1 Background of the Company
1.1.1 Brief History of Pepsi cola

The origins of Pepsi cola traces back to 1898 when Caleb Bradham, a pharmacist in New Bern, North
Carolina, created a curative drinks for dyspepsia called Pepsi cola. Pepsi cola later referred to simply as
Pepsi was a mixture of carbonated water, cane sugar syrup, and an extract from topical kola nuts. To sell
this product, Bradham formed the Pepsi cola company in 1903. In addition to selling the drink at drug
store counters, Bradham bottled Pepsi for sell on store shelves. At this time, bottling was new innovation
in food packaging. However, due to major increase in the price of sugar, Bradham began to lose money
on Pepsi and in 1923, he failed for bankruptcy. The craven holding company of craven country, North
Carolina purchased the companys asset.
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In 1931, Charles G. Guth of the Loft Company, New York City, purchased Pepsi cola the holding
company. Guth had difficulty getting the business going again, but his increased sales by selling larger
bottles at unchanged price. In 1933, Pepsi cola was sold by 313 franchised US. Dealers bottled in the
United States, Cuba and England and sold in 83 countries.
1.1.2 Brief history of Hawassa millennium Pepsi Cola plant

Hawassa Millennium Pepsi-Cola is one of the seven soft drink plants under MOHA, itself a member of
MIDROC Ethiopia group. It is found in the south east of the Hawassa town from a distance of 10km at
the road which leads to Tula. The total compound area is 48km2 and was secured from south nation
nationality and population lease bureau for 99 years on lease basis. Construction of this plant has taken
some times and with the erection of a new state of art bottling line the plant was inaugurated on
September 8/2007, marking the Ethiopian millennium 2000. The total project cost was 180 million birr.
MOHA (Mohammed Hussein Al-Amoidi) soft drinks industry S.C was established on May 15th, 1993
and represented under commercial code of Ethiopia on the 15th of May 1996 acquiring Nifas Silk plant,
Tekle Haimanot plant, Gondar plant and Dessie plant from the Ethiopia privatization agency. The
Company currently has seven operating units, and the recently inaugurated Hawassa plant in SNNPR is
one them and was formed after the acquisition of four Pepsi cola plants located at Addis Ababa (Nifas
Silk and Tekle Haimanot), Gondar and Dessie which were purchased by Sheik Mohammed Hussien Al-
Amoudi on the 18th of January 1996, through BID which was tendered by Ethiopian privatization agency.
The handover of the factories was finalized on the 4th of April 1996. The major products of MOHA soft
drinks industry S.C are: Pepsi cola, Mirinda Orange, 7-up, Mirinda Tonic, Mirinda pineapple and Mirinda
Apple.
1.1.3 Main Products of the company

Hawassa Millennium plant MOHA Soft Drinks Industry S.C. produces the following products:
1. Pepsi
2. Mirinda Orange
3. Mirinda Apple
4. Mirinda Tonic
5. Seven-up (7-up)
6. Mirinda pineapple
These all products are 300ml (0.3L) and machine fills 36,000 bottles per hour. In addition to these, the
plant also produces carbon dioxide gas for the beverage purpose.

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According to the efficiency of producing carbon dioxide, the plant could sell it for home consumption and
supply for consumers who need it for food preservation purpose.
To produce the above-mentioned products, MOHA Soft Drinks Industry S.C got a franchised license
from international Pepsi Cola Company. This company controls the quality and safety of the products in
the market.
1.1.4 Main Customers of the company

Hawassa Pepsi cola plant being producing and distributing the products for local customers, Southern
region of Ethiopia such as Hawassa, Dilla, Hossana, Arban Minch, etc. and some parts of Oromia region
like Shashamene, Bale, Meki, Zeway, Borena etc. And for the future, this company has planned to
distribute its products for the rest region of Ethiopia. In addition, indirectly delivers the products from
company to the customers as follows:
Manufacturers Distributor Retailers Customers
1.1.5 Overall organization of Hawassa Millennium Pepsi cola plant

Hawassa Millennium Pepsi cola plant is a well-structured and adequately staffed organization capable of
satisfying customers need by producing high quality soft drinks like Pepsi cola, Mirinda orange, Mirinda
apple, Mirinda tonic, Mirinda pineapple and 7- up. The company uses combined knowledge and
experience of personnel, from engineers to skilled workers, for consistent quality of products. The
qualified, well trained and committed work-force also enables it to up hold production schedules, even
under adverse circumstances.
All the achievements of the company have been made possible by dedicated efforts of executive and
qualified personnel. The organization of Hawassa Millennium Pepsi cola plant works for a long time in a
day. That is from Monday to Sunday in a week (7-days) and Wednesday is maintenance and sanitation
day. In a day, its work time is 24 hours and sometimes 18 hours. Therefore, the workers have over time
payment.
Employers at Hawassa Millennium Pepsi cola plant are working towards continuing success with the
help of committed leadership and highly motivated work-force by enduring close relationship with clients
+and alliance partners. The company is highly increasing its man power in all level of responsibility and
professional practice pertaining to production work. This has created a relaxed and easy handling of
number of maintenance problems at a time.

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1.1.6 Overall organization and work flow of the company

MOHA soft drink industry, Hawassa millennium Pepsi cola plant the is as shown in figure 1 below:
Plant General Manager
Executive Vehicle
Secretary Maintenance
Supervisor
Human Finance Procurement Technical Production Quality Sales

Resource Manager & Store Manager Manager Control Manager
Manager Manager &Safety
Manager
Personnel General Store & Mechanical Production

supervisor accounts supply maintain- planning & Quality Sales
supervisor supervisor supervisor follow up promotion
supervisor
supervisor
Med & Cost & Procurement Sr. Production

Market unit
safety budget supervisor electrical supervisor Fleet manager
supervisor supervisor engineer supervisor
General Electrical
Territory
Service maintenances Up-country
supervisor supervisors dept
sales manager
supervisor
Account dept
RP &territory
coordinator
Figure 1: Overall organization of the company

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CHAPTER TWO
OVERALL INTERNSHIP EXPERIENCE
2.1 How I get into the company?
Debre Tabor University, Debre Tabor Faculty of Technology has made a good searching for place which
I allowed joining the hosting company by communicating with the plant technical manager before getting
in to the company. This means the co-working of Debre Tabor Faculty of technology, Department of
electrical and computer engineering, and industry linkage supervisor made me get into the company. The
agreement of the hosting company with Debre Tabor University made me to take a letter from the
Department. After this, I gave this letter to the company administration office. Next, the company
administration gave the orientation about the company and told the students the starting day of internship
practice program by shift. So, I have started my practice according to the orientation that they have given.
2.2. The section of the company I have been working in

The company has many sections which help to produce its products. The interesting thing here in
Hawassa millennium Pepsi cola plant is that all the sections of this company are working together with
their synchronized machines. This is to mean that if one of the sections or some machines failed to work
or stop working, then the whole machines in the company will stop working immediately to protect
further fail in other machines. And the synchronization is used for saving power. During my stay in the
company, I tried to see the things that are related to my stream Industrial control engineering and also as
well as Electrical power concepts. They are:
power distribution
Control system
Also from the several sections of the company, I have been working particularly in:
(a) Technical section

(b) Production section

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2.2.1 Power Distribution

The company takes 15KV from EEPCo. this is step down by two transformers, because the company uses
380V 415V. There is also generator from main which is used when power interruption from main
supply and this generator can charge itself when there is power supply directly from suppliers and can
supply enough amount of power for the whole machineries in time of power fluctuation or no supply. But
this generator is not automatic since the power from EEPCo. fluctuates for small period of time which
damages the generator.
To protect the generator, switch ON/OFF manually. Then the voltage described above go to LV (Low
Voltage) room which is sophisticated and it distributed to all machines. The power (voltage) and current
is in phase in any power system; but here, the current lag the voltage because of inductive load. So, it
needs compensation, that means the current and voltage are become in phase by a capacitor using a power
factor corrector. The power factor is 0.97.
In LV room, there are capacitor banks. The uses of these capacitor banks are:
To store a power, then distribute to different sections of the company.

To limit or filter the power used by the company takes from EEPCO.
Here also, main breaker that controls the whole machines in the company. Besides of this, there are also
sub-breakers used to control each machine. For instance, if one wants to control the power in CO 2 plant
room, it is possible to use one sub-breaker. Frequency converter is also found in the LV room to control
the speed of different motors.

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Power distribution of the hosting company:
The overall power distribution of Hawassa millennium Pepsi cola plant is as shown in the figure 2 below:
EEPCO 15KV
Generator
2 Step-down
Transformers
Main breaker
LV Room
Different sub-breakers
Figure 2: Power distribution of the company

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2.2.2 Control system

The control system of the company is programmable logic circuit (PLC), microprocessor, VFD (variable
frequency drivers) are mostly used.
Actuators
Electrical actuator
Pneumatic actuator
Hydraulic actuator
Sensors
A sensor is a device that detects and responds to some type of input from the physical environment. The
plant has different types of photo electric (PE) cells that are used to detect the presence of bottles and to
control the speed of the conveyor belt. There are also different types of proximity and temperature sensors
that installed to perform their purpose. These are:
Resistance thermometry
Temperature sensors
Mercury thermometer
Level sensor
Weight detector
Flow sensor
Since the company control system mostly used PLC and VFD, we will try to discuss them as follows: -
2.2.2.1 Variable frequency drive (VFD)

VFD is a type of adjustable-speed drive used in electromechanical drive system to control AC motor
speed and torque by varying motor input frequency and voltage. There are many and diverse reasons for
using variable speed drive. In general, variable speed drives are used to: -
Match the speed of a drive to the process requirement

Match the torque of a drive to the process requirement
Save energy and improve efficiency
The needs for speed and torque control are usually failed obvious. Modern electrical VFDs can be used to
accurately maintain the speed of driven machine to within 0.1%, independent of load, compared to speed
regulation possible with a conventional fixed speed induction motor, where the speed can vary by as
much as 3% from no-load to full-load.

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The wiring diagram of VFD:-
Figure 3: Wiring diagram of VFD
The benefits of energy savings are not always fully appreciated by many users. These savings are
practically apparent with pumps and funs, where load torque increases as the square of the speed and
power consumption as the cube of the speed substantial cost savings can be achieved in some
applications. The general wiring diagram of a load with variable frequency drive (VFD) includes the
power supply, protection devices, and the frequency drives it-self, the motor and the load.
In actual diagram, the variable frequency drives includes particularly the following modules:
The rectifier module where AC is converted to DC

The DC link module where the rectified DC is smoothened by a capacitors and inductors
The pre-charge module where the capacitor is pre-charged by a DC power before the actual
power is connected to protect it from damaging.
The inverter module where the DC is converted back to AC of variable frequency
The controller module which controls the proper functionality of the drive and monitors the drive
for any undesired status. For example, over voltage, ground-fault, over temperature etc.
Figure 4: Variable frequency drive system
The speed of AC induction motor can be controlled by adjusting the frequency and magnitude of the
stator voltage. Motor speed is proportional to frequency, but the voltage must be simultaneously adjusted
to avoid over-fluxing the motor.

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2.2.2.2 Programmable logic control (PLC)

Programmable logic controls are defined as miniature industrial computers that contain hardware and
software used to perform control function. It consists of five modules:
Central processing unit (CPU)

Input module
Output module
Power supply module
Programming module
The central processing unit (CPU)
It is the heart of the PLC system which controls all PLC activity. It has the processor and memory system.
The input and output module: they are interfaces between the CPU operating at low voltage like 5volts or
less and the field devices operating at higher voltages and currents. There are two basic purposes of input
and output modules.
They are:
To electrically isolate the CPU from the field device

To interface the field devices signals with the microprocessor logic signals
Power supply module: supplies power to the microprocessor and the input output module. The power
supplies for input output units and devices can be AC and/or DC, while the power supply for the
microprocessor and digital circuitry is always DC.
2.3. The work flow of technical and production section

The work flow of general technical and production section of the company is as shown in the figure 5
below.

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Figure 5: Work flow of the section
2.4 Description of the plant

Hawassa Millennium Pepsi cola plant produces six items of soft drinks. These soft drinks are: Pepsi cola,
Mirinda apple, Mirinda tonic, Mirinda orange, Mirinda pineapple and 7-up. Production of above products;

2017
therefore, it takes a series of processes carried out from the beginning to the end. These processes are
carried out by machine with the following capabilities:
Unpacking the bottles

Case washing
Bottle washing
Electronically inspecting bottles for different tests
Mixing ingredients
Filling the products to bottles
Inspecting the bottles for fill level
Date-coding on the bottle showing date of production
Packing the bottles back to the cases
Conveying the bottles and cases in the whole process
2.5 Description of the machine listed above
2.5.1. Case (Crate) Washer Machine

Crate or case washer machine is a machine which is used to wash the crates which are dirtied by the users
or customers. Its operating mode is either manual or automatically. This machine washes maximum of
3900 crates per hour. There are four water pumping motors. Here crates are washed by different
chemicals. Among these chemicals caustic soda which is used as soap, is particularly used.
Figure 6: Crate washer machine
2.5.2. Packer and un-packer machines

Un-packer machine

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It is a machine which is used to separate bottles from crates by lifting the bottles up and then puts them on
the bottles table (conveyer). This machine lifts 96 bottles once by holding unit called grippers. It can lifts
full bottles (96) or less than 96 bottles from four crates. One crate holds 24 bottles and 4 crates hold 96
bottles. There are sensors that detect (sense) whether four crates came or not. If crates which came from
the outside of the machine are not of four, machine wait the rest crates till the crates became of four.
Figure 7: Un-packer machine
Packer machine
It is a machine that is used to put final products (filled bottles) in the crates washed. This machine is
almost the same as un-packer machine. The only difference is that this machine is not lifts less than 96
bottles to put in to four crates. There are a sensor which tells whether 96 bottles are came or not. If 96
bottles came to the machine, machine lifts up these bottles up and put into the four crates. If not, it waits
the bottles until to be 96.
Figure 8: Packer machine
2.5.2.1 Basic parts of packer and un-packer machine

Basic machine
Gripper head with gripper head operating mechanism

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Pack conveyer system

Container conveyance
Minimum container supply sensor
Container supply stop sensor
2.5.2.2 Electrical components used in automating the machine

Maximum container supply sensor
Motors with associated encoder and variable frequency drives(VFDs)
Pneumatic sensors
Photoelectric sensors
Minimum container supply sensor
Container supply stop sensor
2.5.3 Bottle washer machine

Bottle washer machine is a machine which is used to wash the bottles well using different chemicals such
as DIVO NP VB 30, DIVO LEVB 92, Chlorine, DIVO Bright Y 81-5 and caustic. This machine has eight
prime mover (encoder) motors to drive the bottles. In addition, this machine has eight water pump motors
to pump the water on the bottles. It washes maximum of 48,000 bottles per hour.
Figure 9: Bottle washer machine

Synchronous drive motors with their associated encoder and VFDs
Pressure monitoring gauges with limit contact
Temperature sensors and gauges

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Conductivity sensor
PH meter
Solenoid valves
Limit switches
Altera-sonic transmitters and receivers
Force transducer
Level sensor
Pump motors and induction motors
Figure 10: Water flow of bottle washer
Process of water flow in bottle washer machine
High-pressure pre-jetting
Pre- jetting
Caustic 1
Caustic 2
Post caustic
Warm caustic 1
Warm caustic 2
Cold water
Fresh water
The fresh water flows like a cascade through the machine in the direction opposite that of bottle
conveyance. By doing so the content of the tanks are continually rejuvenated. The alkalinity is continually
reduced, and the temperature of re-cooling sections is automatically and optimally graduated.

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A pressure reducer a head of fresh water valves optimizes water consumption by ensuring that the fresh
water pressure is maintained constant. The fresh water feed is shunt off if the machine is stopped. This
prevents unnecessary consumption of fresh water. The last warm water used for intermediate or caustic
free-jetting flows in to the pre-heating section. This results in a heat recovery and at the same time a
gently pre-warming of bottles. The waste water generated during operation of the machine is led in to the
waste water tank via the over-flow of the pre-jetting with the waste water; the high-pressure pre-jetting
for pre-cleaning of the bottle is operated. The waste water overflowing from the waste water tank is led to
in to the drain channel.
Synchronous drive
The synchronous drives rotate in synchronization to the rotating field in the stator because of their design.
The rotating field is specified by a frequency convertor from a speed of zero- to- maximum. It is highly
probable that there is a mechanical overload if the drive fails to start up despite repeated attempts. For
instance, chain, mal-adjustment or blockage of the bottle cell carrier. The gear boxes are protected against
overloading. It should the synchronous position of a drive became miss-adjust all drives are equipped
with an absolute phase angle sensor.
2.5.4 EBI (Empty bottle inspection)

EBI machine is a computerized machine having one control panel and three main independent parts. The
first one controls too tall, too short cap of bottles. The central unit controls the base, inner wall, neck
finish, HF caustic and IR residual. The third part contains sensors, buttons and rejecter. The rejected
bottles are return back to be rewashed or as a waste disposal. This machine detects (checks) maximum of
48,000 bottles per hour.
The EBI machine:

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Figure 11: EBI machine and its components

Cameras
Transmitters
Receivers
Encoders
VFDs
2.5.4.2 The Drive System

The in-feed conveyor is driven by the synchronous motor of the discharge conveyor by means of
a mechanical transmitter.
The guide belts are driven by the synchronous gear motors
The conveyor and guide belt operates synchronously.
The machine speed is infinitely variable.

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2.5.4.3 Detection of Fallen-Over Bottles
Figure 12: Fallen-over container detection
In the left side of the EBI machine, the fallen-over container is not detected the container enters the
machine.
In the right side of the EBI machine, the fallen-over container is detected-the container is rejected
and/or the machine is stopped.
2.5.4.4 Detection of broken, fallen-over, over filled, and under-filled bottles
Figure 13: Detection of broken, fallen over, over filled, and under filled
If container is detected as being over-height, under-height, having fallen-over, or being broken, it will be
rejected.

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2.5.4 Mixer machine

Mixer machine is a machine which is used to mix three different things. These are:
Carbon dioxide (CO2)

Syrup
Water
Mixing ratio of syrup to water: Pepsi cola, 7up, Mirinda tonic, Mirinda pineapple and Mirinda orange are
1:5 but Mirinda apple is 1:4. Amount of CO2 by the volume: Pepsi is 3.5, 7up is 3.7, Mirinda orange is
2.1, Mirinda apple is 3.0 and Mirinda tonic is 4.0
2.5.5.1 Components of mixer machine

i. Product water tank: about 1500 liter of its volume, 42% is product water and 58% is air.
ii. Syrup tank: is a very small tank having 8-liter volume used as temporary storage of syrup.
iii. De-irritation motor: drains out the unwanted soft water. These are two lines; one is product water
and the other is from the chiller.
iv. Water flow meter, syrup flow meter, CO2 flow meter, control valves (air actuator or butter fly
valve) and regulators control the flow of the water, syrup and CO2.
v. Carbonation tank: is about 3000-liter volume tank uses to mix completely these three main
ingredients before passing to the filler machine.
vi. Anton bar: measures CO2, bricks, temperature and density of the product on line reading on
Anton screen.
vii. System body: consists of electrical system (circuit breaker, PLC, communication cable, frequency
inverter, contactors, connecters points and memory card), pneumatic system and Anton system
of the mixer.

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2.5.6 Filler Machine
Figure 14: Filler and its components
Filler machine is a machine which is filled with the products. It fills the products into the bottle which are
washed well. This machine fills the product using the following six steps:
Evacuation
Rinsing
Pressurizing
Filling
Correcting
Sniffing of CO2
If low strength bottle comes to the filler machine, it will be broken because of this filler machine gives the
high pressure to the bottle before it is filled by the product. This machine fills maximum of 36000 bottles
per hour.
2.5.6.1 Automating speed control system

The machines automate speed control system modulates the operating speed, dependent on container
flow conditions prevailing before and after the machine. The operating speed is modulated dependent on
container flow conditions .by releasing and locking the container stop, which in turn, is controlled by
monitoring switches at the container in-feed (discharge). If there is a lack of containers at the backup at
the discharge, the container stop will be locked, the machine will be emptied; the machine will decelerate
to the minimum speed. Once the malfunction has been illuminated, the machine will accelerate to the
preset speed.

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2.5.6.2 Basic components and principles of filler machine

Basic components of filler machine are:
Container in-feed
Container stops
In-feed worn
In-feed start wheel
Carrousel with filling units
Discharge start wheel
Container discharge
Closer
Basic principles of filler machine are:
When the container stop is released the containers are conveyed to the in-feed worn by the
container in-feed worn by the container in-feed.
The in-feed worn increases the spacing between the containers until it correspondence to the pitch
of the in-feed star wheel and the spacing between the filling units.
The container filling units are installed on the carrousel.
During operation, the carrousel rotates together with the filling units. The carrousel
accommodates one empty container from the in-feed star-wheel per filing unit and transfers it to
the discharge star-wheel or discharge conveyer, once it has been filled.
The container will be fed via a star wheel, worn to the closer and be closed.
Afterward, the containers are transferred to the container discharge.
Filling
The containers are filled in several steps the so-called filling phases.
The type and duration of the filling phases are made to satisfy the respective requirements.
The filling phases are time control on machines with pneumatic filling valves.

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2.5.7 Data Coding Machines

This machine is a machine which is used to show or record the data of the production.
2.5.8 Case Conveyor and Container Conveyor
Figure 15: Case conveyor and container
2.5.8.1 Electrical Components Used In Automating the Machine

They are:
Motors
VFDs
Limit switches
Encoders
2.5.8.2 Functional Description

The main function of the conveyor system is conveying cases and bottles throughout the washing, filling
and discharge process.
2.5.8.3 Individual Conveyor System Units

Roller conveyor: the rollers are individually driven via a chain and the drives are protected by guards
Chain conveyor: the closed-loop principle makes use of a drive sprocket and end-turning sprockets.

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Belt Conveyor: the belt conveyor is driven by a drive shaft. The drive is protected by guards. Besides to
the above machines utility lines help prepare an ingredient or a product to be consumed in the course of
production of a product these include:
Carbon dioxide plant

Boiler plant
Chiller and compressor plant
Water treatment plant
Syrup preparation room
Cold room
It is the coordinated involvement of each machine or plant that finally produces the required product. All
the main machines and plants are inter-locked that a fault in one place brings the whole automation to
stop.
2.6 Carbon Dioxide Plant

Carbon dioxide gas is one of the ingredients found in all types of products. Without CO2, any of the
products wont be real. Therefore, CO2 is a mandatory content for the products. At atmospheric condition
the natural state of CO2 is gas.CO2 is a color less, odor less and test less gas, but a significant
concentration of CO2 in air causes a bit sense to nose, mouse and eye. Gaseous CO2 is heavier than air.
The oil is the raw material for the production of CO2. The process of production is started by burnings oil
in the burner. The few gas which among other things contains CO2 and small amount of SO2 is scrubbed
in the fuel gas scrubber where SO2 is removes from the fuel gas scrubber is goes to absorber where CO2is
absorbed by liquid solution of MEA (Mono-Ethanol Amine) in counter flow with the fuel gas. The rest of
the fuel gas leaves the top of the absorber. To take fuel gas through this system an exhauster is installed.
The MEA which absorbed CO2 is pumped from the bottom of the absorber through the lye cooler or
MEA MEA section where it is pre-heated. This continuous to the stripper, where the CO2 is boiled out
the MEA. The stripper is connected with the boiler and from here the MEA which is now without CO2 is
pumped through the lye-cooler (MEAs water section) where its cooled down pumped back to the
absorber. The CO2 together with some steam leaves the top of stripper and goes to cooler where the steam
is condensed and CO2. The purpose of producing CO2in the company is to preserve for a long time
without expired and to sell it for home consumption and supplied for the customers.
Many industries in Ethiopia use CO2, for instance:

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Soft drinks factories

Breweries
Aviation
Welding apparatus
Fire fighting
Green house for growing vegetables
Tobacco industries
2.7 Chiller and Compressor Plant Room
2.7.1 Chiller or refrigerator

Chiller is the machine which is used to produce cold water that used for CO2 and soft drink production by
using Ammonia solution and glycol. Here the cooling process has been done by conduction. The liquid
ammonia cool the glycol, then the glycol cools the water by conduction. The refrigerated water is then
distributed to the production area or section.
2.7.2 Compressor
Compressor are a single storage, oil injected screw compressor driven by an electronic motor. It is a
machine which is used to produce a pure air to distribute different section. There are two air compressors
in the room which work independently. This mean when one compressor works, the other does not works.
Atmospheric air which comes from the outside contains dust, moisture and other gases.
Compressor filter and dried the dust, moisture and the other gases and the pure air stored in pure air
storage tank. This pure air distributed/passed to different machines through different lines. Compressor is
air cooled. The compressor is controlled by Atlascopic Electonickon II regulator. The electronic control
module is fitted to the door on the right side. An electronic cabinet compressing the motor starter is
located behind the panel.
The function of Electronic regulator
Controlling the compressor

Protecting the compressor
Monitoring components subjected to service
Automating restart after voltage failure

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Air compressor is used to collect the atmospheric air by using electrical motors. These motors collect the
air through air sucking valves. Since the collected air is mixture of water, dust particles and other
molecules, it should be filtered to get pure air.
The mixture is separated by fluid oil or light oil after fluid separate the mixture the air moved to the dryer.
In the dryer, if there is mixture in the air, it is moved by air filter. Then it finally stored to pure air storage
tanks and then it distributed to where it needed.
2.8 Boiler Plant

This plant is used for the production of steam, or boils water by using water as raw material. The water
comes from, water section and stored in water storage tanks. This water which is not boiled is purified by
different chemicals such as: salt, confidence 10 and softener. There is water level sensor attached to the
un-boiled water storage tanks in order to detect /sense the level water in the tanks. Boiler uses light and
heavy oil to burn the furnace.
2.8.1 Components of boiler

i. Load controller with in electrical valves : regulates the furnace temperature
ii. Servo-motor: used to spray oil to the boiler which comes from oil tank
iii. Igniter: positive and negative electrode tips rub together to form spark to ignite the boiler
iv. Photocell: has a flame sensor to turn off the spark after igniting the burner
v. Safety valves: keep the boiler from high pressure
vi. Slight glass: used to observe the flame inside the boiler
2.9 The Work Piece or Tasks I Have Been Executing

The work piece or tasks I have been executing are more or less listed below:
Making simple installation
Identifying causes for motor failure
Replacing electrical protective device
Seeing how to read tag number from the electrical material
Arranging the bottles when they fallen from their normal position on the conveyor
Arranging the crowns when it comes to the filler machine in incorrect way
In addition to the above listed I also have been working in the bottling line of the industry. Bottling line
comprises the production line from the inlet of empty bottle up to the output. Within this range there are a
lot of production machineries that has to be controlled by PLC system for safe operation of the line.

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2.10 The Procedure I Have Been Using While Performing my Work Tasks
The procedures that lead me to perform my work tasks are the following:
Reading manuals about the machine that are failed and collecting data from it
Asking the operators and observing when they perform everything around them
2.11 How good I have been performing my work tasks

It is very good when performing my tasks with the operators as well as a manual and that work will be
done /performed well and the problem will be solved.
2.12 Challenges faced me while performing my work

During internship program period, I have faced some challenges. Those challenges lead me to take large
care while performing any work. It also introduced me to take immediate measures after challenges faced.
Some of the main challenges are listed below:
Formation of error while working

Unwillingness of some workers to answer my question during my observation of some machine
Depression due to long hour lives in the company.
2.13 Order to Overcome These Challenges

I have been tried to overcome to challenges that faced while I was performing my tasks. The order that to
overcome the challenges are the following:
I collect all ambiguities and question when the supervisor is over loaded
Then I raised those ambiguities and question at the time he is free.
Taking leisure while I depressed
By making observation repeatedly I minimize the error
Understanding the professional ethics of the work
I have used do it now, and do it right to overcome these challenges
I ask questions by identifying who is concerned for that working areas

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CHAPTER THREE
OVER ALL BENEFITS GAINED FROM INTERNSHIP
Internship program is a method of letting the students to assume themselves as potentially responsible
workman for a particular work by assigning them to actively participating in production control as well as
maintenance in industrial company. And such trends helped me to have valuable work experience.
Internship programs are also potentially valuable to the company. In this internship, I have observed what
the outside industrial world look like more than I know when I was at the school.
When I was at school, I learned or took many theoretically lessen even difficult to understand
theoretically. So, in this internship, I have got good opportunity to solve these difficulties. Because those
things which are theoretically difficult to understand are not hard to understand when I learn practically.
The overall benefits of internship are not limited to the practical skill only. I would like to group the
overall benefits that I have been gained in terms of different categories. Such as:
Improving practical skill
Upgrading theoretical knowledge
Improving inter-personal communication skill
Improving leadership skill
Understanding about work ethics related issue
Entrepreneurship skill
3.1 In terms of improving practical skill

The several courses that I was taken in the class dealt with the theoretical side of engineering. Some
lectures took the initiative and try to illustrate the practical part of this field by displaying graphic images
in their lecture. That was more or less illustrative or even took me to the company to show what the actual
engineering looks like. But these trials were fruitless and failed to give me the clear picture. This
internship program was exactly what I needed to nurture the lack of practical skills I had. Generally, as an
internship student, I was responsible to handle the following piece of works:
Replacing electrical protective devices when they failed, for instance, circuit breaker, lamps etc.
Making simple installation like electrical light installation
Seeing how to read tag number from electrical material and relate it with the wiring diagram
Identifying causes of motor failure and Troubleshooting and maintenance
Electronics/electrical, control/automation system and Variable frequency drives (VFDs)

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3. 2 In terms of upgrading theoretical knowledge

This internship program provided me building my intellectual knowledge and practical skills. The works I
did were mostly related to most courses that I have taken in the class room; especially electrical machine,
power system industrial control system etc. during class time, before the internship, I mainly discussed
PLC, control system, motor winding etc. I covered here application of electronics and digital logic design
like convertor/rectifier and inverter, PLC and motor winding in electrical machine.
3.3 In terms of improving inter-personal communication skill

Inter-personal communication is communication scholar in which numerous ways, always describing
participants who are dependent upon one another and have the shared history. It can involve one to one
conversations or individuals interacting with many people within a society. It also helps me understand
how and why people behave and communicate in different ways to construct and negotiate a social
reality. While interpersonal communication can be defined as its own area of study, it also occurs within
other contexts like groups and organizations.
Company that I have been involved has different people with various background came together. They are
varying in educational level, economic situations, cultural backgrounds, life standards and etc. Since the
aim of the company is to accomplish the work in good way, I need to have good communicative skills.
During my internship, I have improved my communication skill by communicating starting from daily
labor to project manager learning different type of production terms.
3.4 In terms of improving team playing skills

When different individuals come together to work for common goals of the company for increasing
productivity, the most important point is just reaching an agreement on different points on the work to be
done at a time.
A person with good team playing skill will upgrade the following:
To help and co-operate with others
To share ideas with colleagues to openly and willingly
To give comment the team
To demonstrate reliability
To treat others in respectful and supportive manner
To increase the ability of active participant
To become a problem solver on time

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3.5 In terms of Improving Leadership Skill

There is no much place of responsibility given to me to lead any tank. So that I have not got full benefits
from leadership skills during my start at the company; but from the observation of the leader of the
company leading the workers, I understand from the internship to give relevant and important solutions to
the problems.
In terms of improving leadership skills, I offered the following:
To increase my work status

To plan, prepare and schedule all necessary materials
To become more reasons because in action
To know myself and to make self-important
To become accurate and more skill on my judgment
To give technical support
3.6 In terms of Understanding about Work Ethics Related Issues

Work ethics includes both how one feels about their job, career or vocation and how one does his /her job
or responsibilities. It demonstrates many things about whom and how a person is. It also involves such
characteristics as honesty and accountability. Essentially, it breaks down to what does or would do in
particular situation. In my period of internship, I understand what work ethics, one of ethics is
punctuality. To be punctual is duties of every worker that they could achieve their task with the time
given. Some of work ethics are listed as follows:
Reliability
Punctuality
Office disciplines
Honesty
Avoiding potential or apparent conflicts of interest
Co-operation
3.7 In terms of Entrepreneurship Skill

Entrepreneurship skills are making certain individuals able to create a new set of ideas that may help in
the construction stream not only in the production process. But also, any form of activity that has certain
land product to it. During entrepreneurship period, I was not able to come-up with a whole new set of
ideas that were implemented into action. There are different types of entrepreneur skills including
personal traits and management skills.

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CHAPTER FOUR
SYSTEM DESIGN AND GENERAL OVERVIEW OF THE PROJECT
4.1 Introduction
4.1.1 Background of the project

As the time changes and technologies are updating day-to-day its suggestive that using new and
appropriate technologies. There are many advantages in using new technologies to deal with different
types of problems in companies especially industrial areas. As its known that it has economic, social,
environmental and other advantages. In most industrial areas, there are problems regarding failure in
different types of machineries, motors, quality product, cost effectiveness, environmental aspects,
fulfilling the needs of the customer and the likes. So, in dealing with such kinds of problem it is a must
for the companies to use up-to-date technologies. In the company, I engaged during my internship
program (Hawassa millennium Pepsi-cola plant) there is problem with their motor rewinding process
which has big role in different parts of the machineries in the factory. An auto-manual temperature
controlling method by using an oven which can be most appropriate for the problem they have now. By
using Simatic S-7 PLC software it is best way that finding solutions for the company.
4.2 Objectives of the project
4.2.1 General objectives

Designing and analyzing auto-manual temperature controller by using programmed logic
controller for the problem identified.
4.2.2 Specific objectives

To deal with the problem that the company is facing
To study about programmed logic controller
To study about how to design temperature controller by using simatic step-7 software
To analyze how to control temperature manually, by timer and using sensor

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4.3 Statement of the problem

In most industrial companies (factories) especially in the factory which I engaged during my internship
program (Hawassa millennium Pepsi cola plant) have problem with melting the coil and insulating paper
which are primary process in motor rewinding. This let the factory spend money or pay for other nearby
factories (Hawassa textile factory) to rewind their motors for the process of melting coils and insulating
papers inside the motors and also it has negative impact on the production process of the soft drink, with
lower activity (especially time consumption) and quality in production process.
4.4 Solution suggested

As stated earlier there is problem with motor rewinding process. So as an electrical engineering student,
by using Simatic step -7 PLC software I designed an auto-manual oven temperature control with cooling
fun which can solve the problem they face most of the time.
4.5 Methodology of the project

Because of this project needs direct skill manipulation it was a must to refer to some references which are
factory machine manuals, internet access, some electrical engineering books especially industrial control
text books and the likes. I necessarily included both theoretical and simulation using PLC (programmed
logic controller) software which is called Simatic step-7 methods of approaching, including block
diagrams, determination of equivalent circuit parameters.
4.6 Limitation of this project

Since this project has a good impact for industrial factories its necessary for them to implement such a
problem-solving projects. But there are some problems relating to implementing problem solving projects
because of it needs the modeling software which is called Win-CC which is very difficult to get and
companies less communication with trainees.
4.7 Literature review

As the problem is identified in the hosting company it was a must to go on and search for solution for the
problem that the company is encountering. To do this I have been necessarily finding some literatures on
the project entitled auto-manual oven temperature control with cooling fun. But it was not remarkable and
helpful to get related literatures for this project but it was the best option and way to find and search for
some related literatures from some electrical engineering text books, the hosting company manuals and
working manual for Simatic s-7 software. And these references are listed at the last page of this document
or paper. Literatures which are reviewed for this project are mostly from references of the hosting
company manuals, notes on the Simatic s-7 manuals and some electrical engineering text books.
4.7.1 Material Requirement
4.7.1.1 Power Supply

Power supply is a reference to a source of electrical power. A device or system that supplies electrical or
other types of energy to an output load or group of loads is called a power supply unit or PSU. Here in

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this application 5v DC power supply is needed for all electronics involved in the project. So the AC
source, i.e. the source from the power line, has to change to have to a DC source. This requires step down
transformer, rectifier, voltage regulator, and filter circuit for generation of 5v DC power. The Block
diagram of the power supply is shown below:
4.7.1.2 PLC (Programmable Logic Controller)

Programmable logic controller is the automation technique using electronic controllers whose function is
stored in the control device as a program the structure and the wiring of advice are not therefore
dependent on the function of the controller. A programmable logic controller has the structure of the
computer; it consists of a CPU with memory, I/O modules, and internal bus system, the I/O and the
programming language are set up.
4.7.1.3 Normally Open Contact (Address)

Normally Open Contac (---| |---) is closed when the bit value stored at the specified <address> is equal to
"1". When the contact is closed, ladder rail power flows across the contact and the result of logic
operation (RLO) = "1".
Otherwise, if the signal state at the specified <address> is "0", the contact is open. When the contact is
open, power does not flow across the contact and the result of logic operation (RLO) = "0".
When used in series, is linked to the RLO bit by AND logic. When used in parallel, it is linked to the
RLO by OR logic
4.7.1.4 Normally Closed Contact (Address)

Normally Closed Contact (---|/|---) is closed when the bit value stored at the specified <address> is equal
to "0". When the contact is closed, ladder rail power flows across the contact and the result of logic
operation (RLO) = "1".
Otherwise, if the signal state at the specified <address> is "1", the contact is opened. When the contact is
opened, power does not flow across the contact and the result of logic operation (RLO) = "0".
4.7.1.5 SR Set-Reset Flip Flop

SR (Set-Reset Flip Flop) is set if the signal state is "1" at the S input, and "0" at the R input. Otherwise, if
the signal state is "0" at the S input and "1" at the R input, the flip flop is reset. If the RLO is "1" at both
inputs, the order is of primary importance. The SR flip flop executes first the set instruction then the reset
instruction at the specified <address>, so that this address remains reset for the remainder of program
scanning. The S (Set) and R (Reset) instructions are executed only when the RLO is "1". RLO "0" has no
effect on these instructions and the address specified in the instruction remains unchanged.
4.7.1.6 Timer
4.7.1.6.1 S_PEXT Extended Pulse S5 Time

S_PEXT (Extended Pulse S5 Timer) starts the specified timer if there is a positive edge at the start (S)
input. A signal change is always necessary in order to enable a timer. The timer runs for the preset time

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interval specified at input TV even if the signal state at the S input changes to "0" before the time interval
has elapsed. The signal state at output Q is "1" as long as the timer is running. The timer will be restarted
("re-triggered") with the preset time value if the signal state at input S changes from "0" to "1" while the
timer is running.
The timer is reset if the reset (R) input changes from "0" to "1" while the timer is running. The current
time and the time base are set to zero.
The current time value can be scanned at the outputs BI and BCD. The time value at BI is binary coded, is
BCD coded. The current time value is the initial TV value minus the time elapsed since the timer was
started.
4.7.1.6.2 S_PULSE Pulse S5 Timer

S_PULSE (Pulse S5 Timer) starts the specified timer if there is a positive edge at the start (S) input. A
signal change is always necessary in order to enable a timer. The timer runs as long as the signal state at
input S is "1", the longest period, however, is the time value specified by input TV. The signal state at
output Q is "1" as long as the timer is running. If there is a change from "1" to "0" at the S input before
the time interval has elapsed the timer will be stopped. In this case the signal state at output Q is "0".
The timer is reset when the timer reset (R) input changes from "0" to "1" while the timer is running. The
current time and the time base are also set to zero. Logic "1" at the timer's R input has no effect if the
timer is not running
4.7.1.7 CMP? I Compare Integer

CMP? I (Compare Integer) can be used like a normal contact. It can be located at any position where a
normal contact could be placed. IN1 and IN2 are compared according to the type of compression you
chose. If the comparison is true, the RLO of the function is "1". It is linked to the RLO of the whole rung
by AND if the box is used in series, or by OR if the box is used in parallel.
4.7.1.8 Output Coil

Output Coil works like a coil in a relay logic diagram. If there is power flow to the coil (RLO = 1), the
bit at location <address> is set to "1". If there is no power flow to the coil (RLO = 0), the bit at location
<address> is set to "0". An output coil can only be placed at the right end of a ladder rung. Multiple
output elements (max. 16) are possible (see example). A negated output can be created by using the ---
|NOT|--- (invert power flow) element.
4.8 System Design and block diagram
4.8.1 Block diagram of the project

The schematic diagram for an auto-manual oven temperature control with cooling fun is shown in figure
16 below. The power supply and the push buttons (start button and stop button) are directly connected to

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the programmable logic controller as inputs. And the auto-manual controlling is proceeding by the
programmable logic controller. Finally, there is coil which is also directly connected with programmable
logic controller.
POWER
SUPPLY
PLC COIL
PUSH
BUTTON
Figure 16: Block diagram of the project
4.9 Flowchart of the project

The overall flow chart of this project is as in figure 17 below, and the system is start and stop using start
and stop push button and PLC using these the signal make the decision on the output.

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Start/stop
Power supply Output

Program logic control
Stop
Figure 17: Flowchart of the project
4.10 Principle of operation

As stated earlier this project is mainly designed auto-manually. This means it has working principle of
manual, with timer and with sensor. So, its clear that all three working principles cannot work together at
the same time. When the controller is working manually the rest operations (both timer and sensor)

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cannot work or function. When the controller is operating with timer the rest manual and sensor
operational principle cannot function and the same for the operation of sensor.
4.10.1 Manually starting method

Manual starting method is one type of starting method of oven controlling system. Its working principle is
when the operator (user) press the start push button it runs until the user press the stop push button unless
it is running
Figure 18: Manually starting method
4.9.2 Timer based starting method

This is the second type of starting method. The user set or fix the time that varnish and insulating paper of
winding can melt then the time can get the set point. The oven automatically disconnected from power
caring coil.

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Figure 19: Timer based starting method

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4.9.3 Temperature Sensor based starting method

Temperature starting method is used to control the oven temperature if the temperature gets into the
maximum melting point it can be automatically switched off the oven using comparing the actual value
with set point so the user must be set the optimum temperature value.
Figure 20: Temperature sensor based starting method

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4.9.4 The cooling fun

The cooling fun used to cool the motor. When the temperature of the motor is in its maximum point, then
the cooling fun has to be automatically started and the motor starts to cool. If the motor cannot cool down
its difficult to proceed the process due to excess heat. Therefore, its a must to use the cooling fun.
Figure 21: The cooling fun

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CHAPTER FIVE
RESULT AND DISCUSSION
The solid line shows when the controller is operating whether manually, timer based or temperature
sensor based and the dotted line shows that the line is not active and does not operate or working. As
stated earlier the controller operates in three different methods. When it operates manually its lines be
solid and controls and operates manually and the lines of timer and manual will be deactivated, when it
operates with timer based its lines will be active and the rest are not active and when it operates with
temperature sensor its lines be active and the rest will be dotted line or not active. So, I can control the
system with the three methods as its needed. And when if the maximum temperature attained then
automatically it stops the heating process and the fun will be immediately active and starts its cooling
process because it may lead to damage in machineries and other failure in different ways. The overall
circuit of all the starting methods (manual, timer and sensor) in one as figure below shows:
The overall auto-manual starting method simulation:
Figure 22: Simulation of the overall auto-manually starting method

2017
Manual starting method:
Figure 23: Simulation of manual starting method
Timer based starting method:
Figure 24: Simulation of timer based starting method

2017
Temperature sensor based starting method:
Figure 25: Simulation of temperature sensor based method

2017
Simulation of the cooling fun:
Figure 26: Simulation of the cooling fun

2017
CHAPTER SIX
CONCLUSION AND RECOMMENDATION
5.1 Conclusion
From four months (one semester) in internship program, I have concluded that it gives real practical skills
and make students being familiar to the outside industries world. Truly, it prepared me to pay special
attention in all practical activities that will be carried out in the company. Because, of little error or
mistake can leads to large failure in the production process if it is not carried in the correct procedure.
Also, this program allows me to make and develop professional contacts for my future time and it helps
me to know maintenance terms and working standards. And regarding the project it is designed simulated
with different types of starting methods. The proposed solution for the problem of the factory can be used
as a problem solver. Finally, the benefits I offered from the program are: work ethics and team playing
skills, upgrading control and power concepts that I have been seen in the class.

2017
5.2 Recommendation
5.2.1 Recommendation to the hosting company

In this Hawassa millennium Pepsi-cola plant there is no any oven temperature controller for melting coil
and insulating paper process and they spend money for the nearby companies, so I recommend that the
company has to be necessarily finding solution in this way.
Most of the time, when the machine fails to work there is no maintenance for that machine; but it is
replaced by other machine. This leads to wastage of money or extravagancy. So, I recommend the
company to maintain its failed machine by qualified maintainer. The third one is, the company engineer
must train on each machine, especially on hardware control system and PLC in order to maintain the
machine as soon as it has a failure. In addition to this, the CO2 plant must produce in its maximum
capacity to satisfy the necessity of CO2 gas to the company and its customers by maintaining its failed
parts. The motor winder waste a lot of time and labor forces when the motor is rewind, since no winding
machine is in electrical workshop. And finally, The Company has to keep and strengthen the current
positive circumstance.
4.2.2 Recommendation to the University

Debre Tabor University has to work on shifting to using ovens for cooking process as the world is facing
increase in temperature and climate change and using wood for cooking is the main factor for the world
climate change. So, its more appropriate way.
And also, the university has to take the responsibility of placing the students with appropriate companies
because it is difficult for the students to communicate with the hosting companies. Also, the university
should arrange some practical visit in some courses before and after the internship program. Because it
helps the student understands what they are learnt in laboratory and lecture classes easily and Debre
Tabor University should have a closed coordination with the hosting companies to work together. Finally,
the budget allocation for this internship program is not enough for the students to in this program.

2017
References
[1]. Frank D. Petruzella, programmable logic controller, 4th edition, New York, 2011.
[2]. SIEMENS, getting started with Simatic step-7 software (part of documentation package with order
number, 6ES7810-4CA08-8BW0), 3rd edition, 2006.
[3]. MOHA soft drinks, Instruction books, 2006.
[4]. A. K. SAWHNEY, A course in electrical and electronic measurements and instrumentations, 4th
edition, 1985.

2017

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2017

Approval of: - The mentor Mr.Tibebu

DTU, DTUFT, DEPARTMENT OF ELECTRICAL AND COMPUTER ENGINEERING Page i

DTU, DTUFT, DEPARTMENT OF ELECTRICAL AND COMPUTER ENGINEERING Page ii

DTU, DTUFT, DEPARTMENT OF ELECTRICAL AND COMPUTER ENGINEERING Page iii

DTU, DTUFT, DEPARTMENT OF ELECTRICAL AND COMPUTER ENGINEERING Page iv

2.7 Chiller and Compressor Plant Room ................................................................................................. 24

DTU, DTUFT, DEPARTMENT OF ELECTRICAL AND COMPUTER ENGINEERING Page v

4.8.1 Block diagram of the project ...................................................................................................... 33

DTU, DTUFT, DEPARTMENT OF ELECTRICAL AND COMPUTER ENGINEERING Page vi

DTU, DTUFT, DEPARTMENT OF ELECTRICAL AND COMPUTER ENGINEERING Page vii

CPUCentral processing unit

EBI.........Empty bottle inspection

EEPCo.Ethiopian electric power corporation

PLC.programmable logic controller

RLO..Result of logic operation

VFD..Variable frequency drivers

DTU, DTUFT, DEPARTMENT OF ELECTRICAL AND COMPUTER ENGINEERING Page viii

1.1 Background of the Company

1.1.1 Brief History of Pepsi cola

DTU, DTUFT, DEPARTMENT OF ELECTRICAL AND COMPUTER ENGINEERING Page 1

1.1.2 Brief history of Hawassa millennium Pepsi Cola plant

1.1.3 Main Products of the company

DTU, DTUFT, DEPARTMENT OF ELECTRICAL AND COMPUTER ENGINEERING Page 2

1.1.4 Main Customers of the company

Manufacturers Distributor Retailers Customers

1.1.5 Overall organization of Hawassa Millennium Pepsi cola plant

DTU, DTUFT, DEPARTMENT OF ELECTRICAL AND COMPUTER ENGINEERING Page 3

1.1.6 Overall organization and work flow of the company

Plant General Manager

Human Finance Procurement Technical Production Quality Sales

Personnel General Store & Mechanical Production

Med & Cost & Procurement Sr. Production

Figure 1: Overall organization of the company

DTU, DTUFT, DEPARTMENT OF ELECTRICAL AND COMPUTER ENGINEERING Page 4

2.2. The section of the company I have been working in

(a) Technical section

DTU, DTUFT, DEPARTMENT OF ELECTRICAL AND COMPUTER ENGINEERING Page 5

2.2.1 Power Distribution

To store a power, then distribute to different sections of the company.

DTU, DTUFT, DEPARTMENT OF ELECTRICAL AND COMPUTER ENGINEERING Page 6

Power distribution of the hosting company:

Figure 2: Power distribution of the company

DTU, DTUFT, DEPARTMENT OF ELECTRICAL AND COMPUTER ENGINEERING Page 7

2.2.2 Control system

2.2.2.1 Variable frequency drive (VFD)

Match the speed of a drive to the process requirement

DTU, DTUFT, DEPARTMENT OF ELECTRICAL AND COMPUTER ENGINEERING Page 8

The wiring diagram of VFD:-

Figure 3: Wiring diagram of VFD

The rectifier module where AC is converted to DC

Figure 4: Variable frequency drive system

DTU, DTUFT, DEPARTMENT OF ELECTRICAL AND COMPUTER ENGINEERING Page 9

2.2.2.2 Programmable logic control (PLC)

Central processing unit (CPU)

To electrically isolate the CPU from the field device

2.3. The work flow of technical and production section

DTU, DTUFT, DEPARTMENT OF ELECTRICAL AND COMPUTER ENGINEERING Page 10

Figure 5: Work flow of the section