B BBBBBB BBBBBB BBBBBB BBBBBB

RAYA BREWERY 2017
WOLDIA UNIVERSITY
FACULITY OF TECHNOLOGY
DEPARTMENT OF ELECTRICAL AND COMPUTER ENGINEERING
HOSTING COMPANY: RAYA BREWERY SHARE COMPANY
FINAL INTERNSHIP REPORT
By
INTERN NAME ID NO
BERHE DARGO 083/05
INTERENSHIP DURATION FROM OCTOBER TO FEBRUARY
Submission date Submitted to

8/06/2017 Mr. Zelalem Fikadu
RAYA BREWERY 2017
DECLARATION
My name is Berhe dargo I am 5th year Electrical engineering student in WOLDIA University. I
have undertaken my internship experience in Raya brewery share company, from a period of
four months from October to February under the guidance of MR.ZELALEM
FIKADU(Academic advisor) and ENG. YIRGALEM ADDIS (automation engineer) (company
advisor) supervisor of electrical engineering department . I certify that my work is original and
compiled according to the internship report writing guideline given by the Industry Linkage
office of the university.
Name of student Signature Date
Berhe Dargo ________________ ________________
This is to certify that the above declaration made by the candidate is corrected to the best of his
knowledge.
Name of company advisors signature Date
Eng. Yirgalem Addis _____________ _____________
Name of Academic advisors Signature Date
MR.zelalem Fikadu _____________ _______________
FINAL INTERNSHIP REPORT Pre.By. Berhe Dargo (industrial control engineer) Page i
RAYA BREWERY 2017
ACKNOWLEDGEMENT
Firstly, I would like to thank all the people who had assisted me directly or indirectly to complete
my internship program. My first expression of gratitude goes to ENG. YIRGALEM ADDIS
(automation engineer) my supervisor. He gave his full support and advice and guided me till I
were able complete my internship program. I would also like to thanks to Mr. Zemkial
(technical Manager of the company) for his relevant information about the working activities
which is carried out in the factory. I owe my endless thanks to the factory shift team leaders,
(Yalem and Mullugeta) for their best follow up and giving all necessary information and by give
their computers from staring up to end of my report.
And, I would like to give my great thanks; for my academic advisors and my instructor Zelalem
Fikadu for his relevant advice about how to properly work in the company and how to make this
report in short and precise way.
And also, I would like to thank for all electricians, operators and helpers for their continued
advice and assistance how I were improve my practical skill, how I were perform my work task
and how I were able to solve challenges.
FINAL INTERNSHIP REPORT Pre.By. Berhe Dargo (industrial control engineer) Page ii
RAYA BREWERY 2017
EXCUTIVE SUMMARY
In my duration RAYA BREWERY S.C, the first three weeks we started to look the whole
working process of the company, as well as the main raw materials that used and product of the
factories. My final internship report contains all the necessary information about my work
experience that I gained from the Raya brewery factory. The first part describes the background
of the hosting company. And it includes its brief history, main products or services, customers or
the end users of its products or services and the companys overall organization and work flow.
In the second part, the topic that is discussed in detail is the overall internship experience. It
includes details on the process of the section that I have been working in and works that I have
executed. It includes the project that solves the problem of the factory and also challenges that I
have been faced and measures that I took to solve the challenges. In the third part, also discussed
in detail I have gained benefits which helped me to explore my Skills, qualities, abilities and
scope of my theoretical knowledges. Finally I will try to discuss the conclusion and
recommendations for the intern ship report.
FINAL INTERNSHIP REPORT Pre.By. Berhe Dargo (industrial control engineer) Page iii
RAYA BREWERY 2017
Table of Contents
DECLARATION ........................................................................................................................................... i
ACKNOWLEDGEMENT ............................................................................................................................ ii
EXCUTIVE SUMMARY ............................................................................................................................ iii
LIST OF FIGURES ..................................................................................................................................... vi
LIST OF TABLES ....................................................................................................................................... vi
LIST OF ACRONYMS .............................................................................................................................. vii
CHAPTER ONE ........................................................................................................................................... 1
1. BACKGROUND OF THE HOSTING CAMPANY ................................................................................ 1
1.1. INTRODUCTION ............................................................................................................................. 1
1.1.1 Vision ........................................................................................................................................... 1
1.1.2 Mission......................................................................................................................................... 1
1.1.3 Objectives of the factory .............................................................................................................. 1
1.2 MAIN PRODUCTS OR SERVIC OF THE COMPANY................................................................... 2
1.3 MAIN CUSTOMER AND END USERS OF THE COMPANY PRODUCTS ................................. 2
1.4 RAW MATERIALS REQUIREMENT FOR THE COMPANY ....................................................... 2
CHAPTER TWO .......................................................................................................................................... 3
OVER ALL INTERNSHIP EXPERIENCE ................................................................................................. 3
2.0. GETTING IN TO THE COMPANY ................................................................................................. 3
2.1. WHY DO YOU SELECT THIS COMPANY? ................................................................................. 3
2.2. SECTION OF THE COMPANY I HAVE BEEN WORKED........................................................... 3
2.3. WHAT DOES THE WORK FLOW OF THAT SECTION LOOK LIKE ........................................ 3
2.3.1 PROCESS DISCRIPITION OF THESE SECTIONS.................................................................. 4
2.4. WORK TASK I HAVE BEEN EXECUITEING............................................................................. 16
2.4.1 Controlling Mechanisms ............................................................................................................ 16
2.4.2. SENSORS AND THEIR PROPERTY ..................................................................................... 19
2.4.3. Motor controller ........................................................................................................................ 20
2.4.4. Speed control of induction motor.............................................................................................. 21
2.4.5. SERVO MOTOR ...................................................................................................................... 21
2.4.6. Common Causes of Motor Failure and Effect of Motor Failure ............................................... 22
2.4.7. TYPES OF DRIVE IN RAYA BEER FACTORY ................................................................... 23
FINAL INTERNSHIP REPORT Pre.By. Berhe Dargo (industrial control engineer) Page iv
RAYA BREWERY 2017
2.4.8. POWER DISTRIBUTION OF A COMPANY AND COMPONENTS ................................... 23

2.4.9. COMPONENTS OF POWER AND CONTROL PANEL BOARDS ...................................... 24
2.4.10. PROJECT: - CONTROL OF BOILER OPERATION USING PLC ...................................... 27
2.5. PROCEDURES I USED WHILE WORKING ................................................................................ 39
2.6. PERFORMANCE OF WORK ......................................................................................................... 40
2.7. CHALLENGES WE HAVE BEEN FACED................................................................................... 40
2.8. MEASURES WE HAVE BEEN TAKEN TO SOLVE THE CHALLENGES ............................... 40
CH APTER THREE ................................................................................................................................... 41
3. OVERALL BENEFITS GAINED FROM OUR INTERNSHIP ............................................................ 41
3.0. INTRODUCTION ...................................................................................................................... 41
3.1. PRACTICAL SKILL ................................................................................................................. 41
3.2. UPGRADING THEORETICAL KNOWLEDGE ...................................................................... 41
3.3. INTERPERSONAL COMMUNICATION SKILL ......................................................................... 42
3.4. TEAM PLAYING SKILLS ............................................................................................................. 42
3.5. LEADERSHIP SKILLS................................................................................................................... 43
3.6. WORK ETHICS .............................................................................................................................. 43
CHAPTER FOUR....................................................................................................................................... 44
4. CONCLUSION AND RECOMMENDATION ...................................................................................... 44
4.1. CONCLUSION ................................................................................................................................ 44
4.2 RECOMMENDATION .................................................................................................................... 46
Appendix .................................................................................................................................................... 48
FINAL INTERNSHIP REPORT Pre.By. Berhe Dargo (industrial control engineer) Page v
RAYA BREWERY 2017
LIST OF FIGURES
Figure 1. over all organization of the company ............................................................................................ 2
Figure 2. Beer manufacturing process .......................................................................................................... 4
Figure 3.Classic mill ..................................................................................................................................... 5
Figure 4: wart kettle ...................................................................................................................................... 5
Figure 5. Production process of bottled area................................................................................................. 6
Figure 6.De-palletizer machine ..................................................................................................................... 7
Figure 7. Unpacker machine ......................................................................................................................... 8
Figure 8. Bottle washer ................................................................................................................................. 8
Figure 9. Bottle washer ................................................................................................................................. 9
Figure 10. EBI AND VHI ............................................................................................................................. 9
Figure 11. Gap detection ............................................................................................................................... 9
Figure 12. Optical detection ........................................................................................................................ 10
Figure 13.Mouth and base........................................................................................................................... 10
Figure 14.base and Residual liquid inspection........................................................................................... 10
Figure 15.Bottle filling machine with capper ............................................................................................. 11
Figure 16. pasteurizer with its pump motors............................................................................................... 11
Figure 17. Induction motor in pasteurizer ................................................................................................... 12
Figure 18. Labeler ....................................................................................................................................... 12
Figure 19.Video jet Machine ...................................................................................................................... 13
Figure 20. Palletize with control panel ....................................................................................................... 13
Figure 21. keg line ...................................................................................................................................... 13
Figure 22. Keg washer ................................................................................................................................ 14
FigureFigure 23. Production process drought beer ..................................................................................... 15
Figure 24. types of controlling systems ...................................................................................................... 16
Figure 25. CONTROL SYSTEM OF PID .................................................................................................. 17
Figure 26. PLC ............................................................................................................................................ 17
Figure 27. configuration of I/O module to PLC.......................................................................................... 18
Figure 28. Interfacing of PLC and SCADA ................................................................................................ 19
figure 29. servo motors ............................................................................................................................... 22
Figure 30. closed loop control system of servo motor ................................................................................ 22
Figure 31. wiring diagram of power house ................................................................................................. 24
Figure 32. capacitor bank ............................................................................................................................ 24
Figure 33. PLC control panel ...................................................................................................................... 25
Figure 34. AC to DC convertor ................................................................................................................... 26
Figure 35. profibus connection ................................................................................................................... 26
Figure 36. Communication of control panel component ............................................................................ 26
Figure 37. Block diagram of the system .................................................................................................... 30
Figure Figure 38. Water and fuel level control system ............................................................................... 31
Figure Figure 39. pH sensor control block diagram ................................................................................... 32
Figure 40. Block diagram of flow control system ...................................................................................... 33
Figure 41. Overview of dosing chemicals .................................................................................................. 34
Figure 42. Typical mixer motor .................................................................................................................. 35
Figure 43. Industrial boiler process block diagram..................................................................................... 36
Figure 44. General flow chart of the system ............................................................................................... 38
LIST OF TABLES
Table 1 application and its signal flow of plc ............................................................................................. 18
Table 2.Input/output assignments of the project ......................................................................................... 48
FINAL INTERNSHIP REPORT Pre.By. Berhe Dargo (industrial control engineer) Page vi
RAYA BREWERY 2017
LIST OF ACRONYMS
BBT_________________________________________ bright beer tank
CCT ___________________________________________cylindrical canonical tank
CEO____________________________________________ Chief executive Organization
DG1____________________________________________ diagram generator-1
DG2 ___________________________________________diagram generator-2
EBI_____________________________________________ empty bottle inspection
EEPCO________________________________________ Ethiopia electric power corporation
FBI_______________________________________________ full bottle inspection
PLC_______________________________________________ programmable logic control
PID_______________________________________________ proportional integration and derivative
S.C_______________________________________________ Share Company
SCADA__________________________________________ Supervisor control and data acquisition system
Trafo-1_____________________________________________transformer -1
Trafo-2_____________________________________________ transformer -2
FINAL INTERNSHIP REPORT Pre.By. Berhe Dargo (industrial control engineer) Page vii
RAYA BREWERY 2017
CHAPTER ONE
1. BACKGROUND OF THE HOSTING CAMPANY
1.1. INTRODUCTION
RAYA BREWERY P.LC.is located on the outskirts of Maichew town,670km north of Addis
Ababa in the Tigray regional state. It is an Ethiopian private company established under 58
founder members the number has now grew to 2441 shareholders. It engaged in the
manufacturing and distribution of high quality beer and drafts in Ethiopia. The climate of the
area is pleasant for most of the months. Its attractive climate together with beautiful Landscape
makes the city well suitable for residence. The designed and attainable production capacities of
the plant are 600,000 hectoliters annual and generate employment opportunity for about 400
workforces. The Factory is registered with a total paid up capital of 1.7 billion birr. The factory
has a formal promise to produce and supply high quality products at competitive price and fast
delivery of products at the right time. The Factory uses modern machineries importing from two
European countries i.e. German and Czech Republic companies, standard raw materials,
qualified & experienced manpower.
1.1.1 Vision
To become a premium craft beer brand in Ethiopia.
To grow the company festally.
To become premium craft beer brand in east Africa.
1.1.2 Mission
Of Raya brewery Share Company is to produce unique quality beers.
To operate in ethical and environmentally friendly standards while hand crafting our
product.
To produce a unique quality beer that is second to none.
1.1.3 Objectives of the factory
To produce and supply high quality beer products to the local and international markets at
competitive prices and provide steadfast customer services
To contribute to the poverty reduction strategy of the country by creating market jobs for
citizen.
[Type text] Page 1

RAYA BREWERY 2017
1.2 MAIN PRODUCTS OR SERVIC OF THE COMPANY

The main products of the company are:
High quality beer

Quality draft
1.3 MAIN CUSTOMER AND END USERS OF THE COMPANY PRODUCTS
The company manufactures and distributes high quality beer in order to meet maximum
customer satisfaction. The main customers and end users of RAYA BREWERY S.C. are the
peoples of Ethiopia and some peoples of east Africa. The Factory's products are distributed
throughout the whole country Ethiopia.
1.4 RAW MATERIALS REQUIREMENT FOR THE COMPANY

The main row materials to the brewery factory are:
Malt, Yeast, Hops and Water
1.5. OVERALL ORGANIZATION AND WORK FLOW OF THE COMPANY.
Board of directors
CEO
Production Procurement Project Finance

Commercial
and and sourcing manager and
director
technical director administra
director tion
Production Technical
Sales
Finance
Logistics Planning
HR and
Marketing
administration
procurement
Figure 1. over all organization of the company
FINAL INTERNSHIP REPORT Pre.By. Berhe Dargo (industrial control engineer) Page 2
RAYA BREWERY 2017
CHAPTER TWO
OVER ALL INTERNSHIP EXPERIENCE
2.0. GETTING IN TO THE COMPANY

As they promised earlier on the confirmation paper to host me for four month internship, I arrived with a
letter that was send from WOLDIA University to the head office of MPM of the Company. The human
resource development reported to the general manager. He tells to the technical department head to give
me a task related to my department. And the technical department head introduced me to automation
supervisor. They assigned me to work with the electrical maintenance .I have been worked for four
months from October to February.
2.1. WHY DO YOU SELECT THIS COMPANY?

I select raya brewery Share Company because of the following reasons:
It is a new industrial technology so in order to familiar with these new technology
It uses many electrical instruments and controlled materials on its application.
It found in our home place.
2.2. SECTION OF THE COMPANY I HAVE BEEN WORKED

I have been working mainly in production (bottling) section of the company, why? Because in this section
have so many electrical components and so many controlling systems like relay, plc control systems but I
try to cover all the production lines as much as possible because of all section have their own controlling
systems for example the other three sections like brew house, filtrations and fermentation, and utility uses
PID, SCAD, PLC and relay type control systems so because of that I try to cover all section of the
company.
2.3. WHAT DOES THE WORK FLOW OF THAT SECTION LOOK LIKE
The work flow of these four sections of RAYA BREWERY S.C. is as shown in the figure below:-
RAYA BREWERY 2017
Figure 2. Beer manufacturing process
2.3.1 PROCESS DISCRIPITION OF THESE SECTIONS

1. BROWNING HOUSE: It is the first section at which the component of the malt is converted to soluble
products and in particular soluble fermentable sugar.
Drum sieve: is used to avoid unwanted materials like a very little stones, little malting and also
used to drumlin the barely and have one part which is called de-stoner.
DESTONER MACCHINE: is a machine that used to separate stone from the malt.
ASPIRATION MACHINE: is used to select the dust and pure malt then reject the dust.
Milling Machines: is a power driven machine that cuts the malt by means of a multi tooth
rotating cutter. Milling is a process of producing flat and complex shapes with the use of multi-
tooth cutting tool, which is called a milling cutter and the cutting edges are called teeth.
RAYA BREWERY 2017
Figure 3.Classic mill
MALT HOPPER: is used to hold and store the powder of the malt.
PREMASH: is used to mix both the cold water and hot water 0degree and 78degree Celsius
respectively.
MASH KETTLE TANK: is used to measure the amount of ph. The main advantage of mash
kettle is to convert starch to simple sugar.
MASH FILTER: is used to separate the spent and beer. The beer is going in to wart collector
which is tempo rarely storage. It has 72 plates and 2 bodies to filter and it have capacitive sensor
to control weather it work or not the mash.
WORT KETTLE (PAN): After the mash filtration, the next step is the wart boiling.
Its main purposes are the elimination of unwanted volatile compounds.
Figure 4: wart kettle
WHIRL POOL (WHIRL SETTLING): is the final process in brew house hat is used to
separate the trub from the west. After this process the wart is going to the fermentation house.
the wart is cooled down at 92c degree
WART COOLING (Heat exchange): Heat Exchangers Found between brew house and
fermentation. The Wart is cooled down from 92c degree to 8-10c, because yeast can only live
and ferment at low temperature.
2. FILTIRATION AND FERMENTAION
Fermentation tanks (CCT): Fermentation serves as: The foundations of the brewing process the
conversion of wart into beer. Here, the yeast converts fermentable sugars created during mashing to
RAYA BREWERY 2017
alcohol, natural carbonation (CO2) and compounds that determine the ultimate flavor profile of the beer
and also fermentation is the process of chemical reaction. In fermentation yeast is mix with beer in pump
after they introduce to the CCt. In fermentation both yeast and beer are waited for two week (15 days
only).
Filtration: is used to bright the beer from the yeast. Through beer filtration, brewers strive to remove
suspended particles of yeast, protein and silica gel, resulting in a clear, finished beer.
Separator: is first filter that is used to separate the beer and waste but it cannot be completely
separate.
Candle filter: is completely filtering the beer from the waste. After that the beer will store in
buffer tank2.
Blending carbonate: In order to achieve the finished product specification for CO2, the beer is
carbonated before being sent to the bright beer tanks. Nitrogen gas may also be used in small
quantities to favor foam performance.
Bright beer tank (BBT): Final processed beer stored in the BBT until the beer is required by
bottling department and serves as temporary storage for finished beer.
3. PRODUCTION OR BOTTLING AREA: Is one of the important sections in brewing process w/c uses
complex machine and plant to maintain high quality of beer and to increase the demand of customer by
excellent presentation of the product. In this section two types of packaging are takes place;
A. Bottled Beer B. Kegging(Drought Beer)
A. Bottled beer: Raya-Brewery uses bottle filler having filling capacity of 36000bottles/hr without time
that take place which bottles can contain 330 ml.
Figure 5. Production process of bottled area
RAYA BREWERY 2017
The first step in the bottling house department is:
1. De-palletizer: It is a machine used to load empty bottle crate that comes from customers to be rolled
conveyor and pass to uncaser. It is usually performed layer by layer by pushing the crate with bottle
together and displacing or lifting the layer by pneumatically operated gripper. The de-palletizer
removes the crates (50crates) and presents them to the unpacker machine. Various mechanical
principles, design configurations and control methods can be used in such machines according to the
situation needs and the supplier chosen. The present tendency is to use proximity switches and solid
state photo electric cells (PEC's) as sensors connected to programmable logic controllers (PLC's)
which control the actions.
Electrical part: in this section the electrical parts are
Servo motor to up and down the griper
Induction motor to run the conveyor
Ultrasonic sensor to sense the presence of any object
Photo electric sensor to sense the presence of crates on the pallet
Starting method:
Forward reverse method for the servo motor
Direct online method for the induction motors
Control method:
by varying supply frequency using inverters i.e. Danfoss& Acopos
Figure 6.De-palletizer machine
2. Un-packer: It is a machine which is used to lift empty bottles from the crates and sends the crates to the
crate washer, the bottle to the bottle washer. The bottles are lifted from the crates by gripper heads and
placed on a large conveyor from where they are transported to the sorting machine. This machine moved
by using the induction motors and this motor is control by PE sensors. The un-packing of bottles from
crates is performed by unpacking machine.
Electrical part in unpacked machine
Photo electric sensor
RAYA BREWERY 2017
Photo electric sensor with counter to arrange the position of the crates
Servo motor to run the robotic machine run up and down wards
Figure 7. Unpacker machine
3. Crate washer: -After the bottles fall, the crates will travel to the crate washer which washes the
crates through the conveyor with water by two consecutive levels. Its used to wash the crate, then
washed bottle crate moved to caser machine to put down finished bottled beer. The aim of this washer
is to wash the crate as needed and this is done by,
I) by inverting the crate up and down so that any broken glass or any unwanted materials removed from it
ii) By washing the crate by using hot water at 50octemperature and caustic soda acid in order to found
perfect and clean crate.
4. Bottle washer: The bottle to cleaned are delivered to the bottle washer by a slat conveyor chains
40*542 = 21680 bottles by ones time. The entire process takes place 10 to 15 minutes
Figure 8. Bottle washer
The bottles to be cleaned passes through the following stages

I) Pre Soak is a stage in w/c the bottles are turned upside down to empty them of any liquid, cigarette
butts or other fragments. If these items are not effectively removed in this stage, they can disintegrate in
the bottle washer & plug nozzles.
ii) Immersion Soak: Is second zone of bottle washer w/c has three baths (caustic1, caustic2 & caustic3).
the emptied bottles are immersed in a bath of caustic and then the same caustic solutions jetted again over
the bottles in order to remove remaining parts of labels w/c have been soaked off but still in the bottle.
RAYA BREWERY 2017
iii) Post Caustic: This third zone is used to cleaned (remove) the remaining caustic from the immersion
soak.
Warm water1 and Warm water2:-Which has the same purpose & used to remove remaining caustic
after post caustic washing. After the last stage (fresh water stage) the remaining moisture in the bottle is
removed by sacking pump at lower temperature is takes place to obtain a step wise cooling and this leads
to complete cooling & removal of all residues.
Figure 9. Bottle washer
Electrical part:
Ac motors to pump the caustic soda, fresh, cold &hot water
Temperature sensors
5. BOTTLE INSPECTION:-Basically all bottles should be clean and fit to use after cleaning.
Figure 10. EBI AND VHI

VISUAL INSPECTION: removes bottles which have crack on their neck and others manually. EMPTY
BOTTLE INSPECTION (EBI): Is used to inspect the empty bottles before it goes to filler. The
following parameters are to be checked.
a. Optical (or Mechanical) gap detection- stops machine when detecting bottles or gaps in bottle flow.
It is used to avoid damage to the machine & unwanted production steps.
Figure 11. Gap detection
RAYA BREWERY 2017
b. Optical detection of too high /short bottles- generates rejection signal when detecting too high
/short bottles according to the program given to the machine. Faulty bottles are rejected by a pusher
installed at the bottle outlet. It is used to avoid unnecessary production step.
Figure 12. Optical detection
c. Mouth and base finish inspection (Camera technology)-A bottle neck finish is illuminated from
above by a dome type LED and the camera takes an image of the bottle neck finish and converts the
signal in to digital image data.
Figure 13.Mouth and base
D.Base inspection-is camera technology to inspect liquid and varying conductivity of the Individual
media (air, glass, water, caustic).
Figure 14.base and Residual liquid inspection
Electrical part:
we use photo electric sensors to detect the height of the bottle
RAYA BREWERY 2017
pusher used for rejection of over or under the needed height
pusher for rejection case
6. FILLER:-The bottle filler in Raya Brewery is rotary machine and contain 91 filling valves and can
fill at 600 bottles per minute. The machine can be networked having filling capacity 36000btls/hr.
Generally this machine is working with AC motor, which is synchronize motor and by using
inductive and capacitive sensor.
Figure 15.Bottle filling machine with capper
7. CROWNER
The filled bottles are immediately sealed with crowing machine. The corks from sealed Carton are
transferred to cork hopper through magnetic conveyor.
8. Full bottle inspection (FB1)
This is used to inspect weather the bottles, which has not crowned, under filled and over filled are
rejected by FBI and after rejected the bottles are removed by the operator. The under fill or over fill beer
is rejected by photo electric cell sensor and moving by AC motor.
9. PASEURIZER
Figure 16. pasteurizer with its pump motors
RAYA BREWERY 2017
Pasteurization is simply means to destroy or to reduce the number of harm full microorganisms in a
product in order to increase its biological stability. The objective is the effective kill of harmful organisms
with the minimum use of energy that can grow and cause beer spoilage in the bottle. The tunnel
pasteurizer in Raya Brewery has pasteurization capacity of 36,000btls/h and one bottle at least 40min to
be pasteurized. In the pasteurizer there are 10 Induction motors. The pasteurizer operates as put in a series
of zones. The first three motor are heating zone (28 -49c), the next four motor are pasteurization zone
(60-65c) and the last three motor cooling zones (47-27c). The bottles are loaded at one end and then
conveyed under a series of water sprays.
Figure 17. Induction motor in pasteurizer
10. LABELER
Labeler is decoration of the bottle that uses for market share, the appearance of the bottle is very
important. The companys uses Topmatic krones Cold-glue labellers it has Container-table diameter:
1,800 mm Maximum machine output 72,000 bottles per hour.
Figure 18. Labeler
11. Full Bottle Inspection (FBI): also Called Checkmate. It is a machine which contains a light
dependent sensor. This sensor is used to select:
Under fill and over fill bottles.
Uncrown/unsealed bottles.
Miss labeled bottles and Identifies production bottle or not.
RAYA BREWERY 2017
The above parameters are checked with sensors which sense the radioactive ray & crones camera system.
If one of the above parameter is not satisfied the beer bottle will be pushed by mechanical pusher
(rejection unit).
12. Video jet Machine: The main function of this machine is to print the production date, the name of the
Production Company and expired date of the beer. In this we dont have any sensor that detects the
incoming of bottles but it uses encoder of the servo drive to print these bottles by using gamma ray.
.
Figure 19.Video jet Machine
13. PACKER MACHINE: The packer is from the crate washer are conveyed by belt conveyer to packer
(packing machine). The finished bottles must now be picked on the conveyer and inserted in to crates
so the Imamate picks 4 crates of bottle (96 bottles) at once and inserts in to the crates having capacity
of 2000btls/h and those crates filled with bottles are conveyer. These are sensors (photo cells) which
used to check other unwanted materials in which the machine will stop operation. This sensor
operates with the combination of transmitter & receiver, exactly the same as the Unpacker.
14. PALLETIZER: It is a machine used to load full bottle crate that comes from caser to be rolled
conveyor and pass to output. This palletizing process is done automatically. The Palletizer built five
layers of crates on the pallet totally 50 crates containing 1200 bottles are built on it.
Figure 20. Palletize with control panel

B. Kegging (Drought Beer)
Figure 21. keg line

RAYA BREWERY 2017
Draught beer is filled by keg. A keg is a standardized cylindrical metal barrel made of chrome nickel
steel. Advantages of kegs are: all conveying and storing process can be automated, cleaning, sterilizing
and filling can be automated, and they are closed vessels with automatic leakage detection and require
fewer manipulations. Steps in the draught beer:
The filtered beer comes from bright beer tank through beer lines and enters to heat exchanger and also hot
water enter in one line to heat exchanger, the heat exchanger has plates it used for heating of the surface
of heat exchanger, then the beer pasteurized at 74c for 30 second.
2. EMPTY TURNING MACHINE: also called empty inverter machine. it accepts kegs from the input and
uses to invert the keg. Again passes to the external washer machine.
3. EXTERNAL WASHER MACHINE: it is a machine used to wash the keg external.
Figure 22. Keg washer
4. INTERNAL WASHER AND FILLER: in Raya Brewery share company there are two internal washer and
filler each. The process of internal keg cleaning and filling has three stations. Stage-1: first pressurizing
the keg, to remove residual product in the keg and rinsing by water. Stage-2: Blowing out of water, rinse
by caustic, blowing out of caustic and rinsing by hot water. Stage-3: Blowing out hot water with steam,
steaming, venting & CO2 pressurizing and filling of drought beer.
5. RATING SYSTEM: also called weight sensor. Used to check the weight of the full keg If the full keg
is under and over fill, they push by the pusher.
6. LABELING: The labels carry important and effective imprints used to decorate the bottles, glues are
used to stamp the papers with the kegs.
7. VIDEO INJECT: used to write the shelf life of the drought.
8. FULL TURNING MACHINE: also called full inverter machine. it accepts kegs from the filler and uses
to invert the keg. Again passes to the output.
RAYA BREWERY 2017
FigureFigure 23. Production process drought beer
UTILITY HOUSE:
To run a brewery, as in other industries, utility installations are necessary.
These comprise:
Boiler Plant
The processes are supplied with heat from a boiler plant. The heat is available to the various consumers as
steam or high temperature hot water. Oil, natural gas, biogas or coal may be used as fuel for the boiler
Cooling Plant: Process cooling is supplied from a cooling plant using reciprocating, screw or
centrifugal compressors. The cooling at the consumers may take place directly by expansion of a primary
refrigerant mostly ammonia or indirectly by use a secondary coolant such as propylene glycol.
Water Treatment Plant
Water can be supplied from wells or surface intake. If the water is supplied from own intakes, it must be
treated in conventional water treatment plants. The water quality typically meets requirements for
drinking water.
CO2 Recovery Plant: The CO2 generated during the fermentation process can be collected and
cleaned and then reused for the process. CO2 is necessary for carbonating and for counter pressure in
tanks and bottles. If no CO2 recovery plant is installed, the brewery has to buy CO2 from outside.
Compressed Air Plant: is mainly used for instruments, pressurizing of tanks, actuators and possibly
brewers grains transport. The compressed air is supplied from a compressed air plant.
Waste water treatment
The water which is used by the company must be treated and neutralized in order to stabilize the PH
value. In this section we use level, photo electric and inductive sensors in the treatment tanks. And also
the process is automatically controlled by the plc program.
RAYA BREWERY 2017
2.4. WORK TASK I HAVE BEEN EXECUITEING
I have been executing various duties assigned by our company supervisor such as study the different
types of controlling systems, controlling speed of induction motor, study types of sensors and different
application of PLC, study of power panel and control panel components of this company. I also try to
solve the company problem by making project which is controlling of boiler using PLC. Before we have
been practicing in these work tasks at first I was simply looking how they do it since it was my first
practical experience. After that I have been working in collaboration with my company supervisor and
electricians for efficient work.
2.4.1 Controlling Mechanisms
The company is very huge and modern one, it implement modern control techniques such as SCADA,
PLC to control actuators such as relays and valves. Mainly PLC and SCADA control almost the whole
company process. Inputs to, and outputs from, a PLC and SCADA are necessary to monitor and control
motors and process sequence. Both inputs and outputs can be categorized into two basic types; logical or
continuous (i.e. analog or digital).
Figure 24. types of controlling systems
1. Concept of Relay Function

A relay, or contactor, is an electromagnetic device composed of a frame (or core) with an electromagnet
coil and contacts (some movable and some fixed). The movable contacts (and conductor that connects
them) are mounted via an insulator to a plunger which moves within a bobbin. A coil of copper wire is
wound on the bobbin to create an electromagnet. A spring holds the plunger up and away from the
electromagnet. When the electromagnet is energized bypassing an electric current through the coil, the
magnetic field pulls the plunger into the core, which pulls the movable contacts downward. Two fixed
pairs of contacts are mounted to the relay frame on electrical insulators so that when the movable contacts
are not being pulled toward the core (the coil is de-energized) they physically touch the upper fixed pair
of contacts and, when being pulled toward the coil, touches the lower pair of fixed contacts.
2. PID Controller
A proportional-integral-derivative controller (PID) is a feedback controller that is widely used in many
control applications. The main function of PID controller is to minimize the error, A PID calculates the
error between the measured process variable and desired set point and then gives a corrective action to
RAYA BREWERY 2017
adjust the process according to the set point and to keep the error as low as possible. The proportional
term gives reaction based on the current error; the integral value determines the action based on the sum
of recent errors and derivative value gives the reaction based on the rate at which error changes. The
combine action of these three parameters helps in generating a control signal to adjust the process to the
desired value. The PID controller gives the manipulated variable (MV) which is the weighted sum of its
three correcting terms namely proportional, integral and the derivative.
Figure 25. CONTROL SYSTEM OF PID
3. Programmable Logic Controller (PLC):

A PLC is a computer type device used to control industrial process. PLC connected with input output,
sensors &actuators. It read limit switches, proximity switches, photoelectric switch, flame detectors,
motion detectors, and analog process variables such as temperature, pressure distance. On the actuator
side PLC operates electric motors, pneumatic or hydraulic cylinders, and magnetic relays, solenoids or
analog out
Figure 26. PLC
The most essential components are:

CPU:
This is the brain of PLC that retrieves, decodes, processes and Stores
information.
It also executes the control program stored in the PLCs memory.
It functions much the same way as the CPU of regular computer, except that it
uses special instructions and coding to perform its function.
I/O system
RAYA BREWERY 2017
It is the section of PLC to which all the field devices are connected.
(Field devices such as switches push buttons, sensors, motors, lamps etc)
The I/O system physically carries out the control commands from the PLC.
The I/O can be considered as the arms and legs of the PLC.
Power Supply
It provides the required voltage and current to the PLC
This can be built into the PLC or it can be an external unit.
Common voltage levels required by the PLC are 24Vdc.
Indicator lights
Indicate the status of the PLC including power on, Running mode, Pause mode and Fault.
Indicate the status of the PLC including power on, Running mode, Pause mode and Fault.
Figure 27. configuration of I/O module to PLC
Table 1 application and its signal flow of plc
Application of PLC in a company

For counting.
For timing.
For data transferring and data shifting.
For controlling of motor operation.
Motion control And so on.
signal flow of plc system
RAYA BREWERY 2017
4. SUPERVISORY CONTROL AND DATA ACQUISITION SYSTEMS (SCADA)
SCADA stands for Supervisory Control and Data Acquisition. As the name indicates, it is not a full
control system, but rather focuses on the supervisory level .SCADA systems are used to monitor and
control a plant or equipment in industries such as telecommunications, water and waste control, energy,
oil and gas refining and transportation. These systems encompass the transfer of data between a SCADA
central host computer, number of Remote Terminal Units (RTUs), Programmable Logic Controllers
(PLCs), the central host and the operator terminals
Where is SCADA used?
Water and Wastewater utility fermentations
Power distribution filtrations
A SCADA system performs four functions:
1. Data acquisition 3. Data presentation
2. Networked data communication 4. Control
The functions are performed by four kinds of SCADA components:
1. Sensors (either digital or analogue) and control relays that directly interface with the managed system.
2. Remote telemetry units (RTUs). These are small computerized units deployed in the field at specific
sites and locations. RTUs serve as local collection points for gathering reports from sensors and
delivering commands to control relays.
3. SCADA master units. These are larger computer consoles that serve as the central processor for the
SCADA system. Master units provide a human interface to the system and automatically regulate the
managed system in response to sensor inputs the communications network that connects the SCADA
master unit to the RTUs in the field.
INTERFACING OF PLC AND SCADA
Figure 28. Interfacing of PLC and SCADA

2.4.2. SENSORS AND THEIR PROPERTY
A sensor is a device that receives a stimulus and responds with an electrical signal. The stimulus is the
quantity, property, or condition that is sensed and converted into electrical signal.
We may say that a sensor is a translator of a generally nonelectrical value into an electrical value.
Typical examples of sensors in the factory
RAYA BREWERY 2017
Proximity switch no physical contact between object to be sensed and the sensor. these are
some of them
Inductive proximity switch: -use an electromagnetic field to detect the presence of
metal objects. It senses metal object when the metal is near to the inductive sensor the sensor
changes its state from NC to NO or from NO to NC.
Capacitive proximity switch: -Use an electrostatic field to detect the presence of any object.
The object to be sensed is nonmetallic.
Application of capacitive proximity switch
Level sensing
Presence of any nonmetallic object
Temperature sensors
Thermocouple (burner ,boiler & dryer out let)
2.4.3. Motor controller
A motor controller is a device or group of devices that serves to govern in some predetermined manner
the performance of an electric motor. We can control motors in hard ware either manually or
automatically by using the following electromechanical components.
Contactors:-is an electrically controlled switch used for switching power circuit.

Pushbutton: - is a switch which is used to either open or close of an electrical circuit depending on
the application. This switch has two types. These are normally open pushbutton (NO) which can be
identified by green color normally close pushbutton (NC) which can be identified by red color.
Time delay relay (timer):- time delay relay is a relay which provides a mechanism for turning a
device on or off after a predetermined amount of time.
Fuses: its essential component is metal wire or strip that melts when too much current flows through
it, interrupting the circuit that it connects. It protects the circuit against short circuit and overloading
but the fuse must be replaced after fault occurred. The main function of the fuse is to prevent damage
to the motor, cable and contactor by limiting the energy during a fault.
Breaker:-is automatically operated electrical switch designed to protect an electrical circuit from
damage caused by overload or short circuit. Its basic function is to detect a fault condition and
interrupt current flow. Unlike fuse which operates once and then must be replaced breaker can be
reset either manually or automatically to resume normal operation.
RAYA BREWERY 2017
Overload Relays: - are protective device they are designed to cut power if the motor draws too much
current for an extended period of time. Overload relay contain a NC relay. When excessive current flows
through the motor circuit the relay opens due to increased motor temperature, relay temperature or sensed
overload current.
Cables
The IEE Wiring Regulations include protection of cables by fuses and an equation is given for the
calculation of a relationship between fuses and cable characteristics.
2.4.4. Speed control of induction motor
The speed of AC motor is given by
There for, the speed of AC motor can be controlled by varying the number of poles or by varying the
supply frequency. From this point of view methods used to control the speed of AC motor in the factory
are:-
Frequency converter (frequency inverter)
This is usually called variable frequency drive (VFD).It is the most popular speed control of ac
motors in industries due to the following reasons:-
Energy Savings: - as the operating speed of the motor reduces the horsepower required to
operate the system also reduced.
Multi-Motor Control: - some frequency inverter can control multiple motors from the
same inverter which can be an advantage over other type of speed control methods.
Improved process control: -it can take process control signal inputs for start/stop and
speed control and its output signal to DC and PLC systems.
2.4.5. SERVO MOTOR

Servo-motor is asynchronous motor which can approach and maintain various programmable positions.
They are mainly used because of minimal space requirement, flexible and robust design, and wide range
of combinations with low noise operation. Measuring takes place via an encoder e.g. a resolver,
incremental encoder, or an absolute value encoder. The electronic controller compares the signals of
this encoder with define position set value.
RAYA BREWERY 2017
figure 29. servo motors
Precision, dynamics and power in particular compact design-high performance servomotors

stands for these qualities. They can be used even in the smallest space thanks to the motor that
was optimized with regard to length. The tasks of servo drive control is Synchronous operation
of all drives independent of the operating state
Figure 30. closed loop control system of servo motor
NOTE: - In a company uses more AC motors rather than DC motor due to the following reasons:
Less environmentally in sensitive good power factor.
Low cost for use.
Low maintenance.
Physically smaller than DC motor of the some horse power can be run at speeds above the
nameplate rating.
2.4.6. Common Causes of Motor Failure and Effect of Motor Failure

Motor failure can be caused by various conditions but the most common causes are
1. Thermal break down
Causes for thermal break down
Overload Voltage variation
RAYA BREWERY 2017
Single phasing Improper ventilation

2. Mechanical break down
Bearing failure resulting in rotor or stator
Most common causes of bearing failure are:-
Improper lubrication Moisture/water
Excessive belt Corrosion/chemicals
Misalignment Rodents and insects
Environmental break down Age
3. Effect of motor failure
The most effect due to motor failure is
Loss of production and Cost for equipment replacement
Collateral equipment damage and Work in process damage
Over time for repair crews
2.4.7. TYPES OF DRIVE IN RAYA BEER FACTORY
In the Raya beer factory there have so many drives like:
1. Acopos drive: it is frequency converter that controlled to the servo motor. In this drive
there is no loss of power.
It is accept and send massage to the PLC controller by using feedback.
2. Danfoss drive: it is also frequency converter that control to the synchronous motor
There is a loss of power in this drives
2.4.8. POWER DISTRIBUTION OF A COMPANY AND COMPONENTS

The power source of Raya brewery share company is hydropower, 400KV power generations
from super grid (Addis Ababa). Through a transmission line comes in to Alamata substation, it
accepts 132KV for original grid; through step down transformer of the second substation
(Maichew substation) accepts 56kv. At the receiving transmission voltage is 15 KV and step
down by transformer to 380V. This power distribution in to the company is three phase.
Electrical motors and other heavy loads in the company are connected to the three phase wires.
In the case of small loads like lamps, refrigerators, heaters and funs are connected single phase.
RAYA BREWERY 2017
A. TRANSFORMER: A transformer is a static or stationary electromagnetic device, consisting

of two coils, by means of which electrical power in one circuit is transformed into electrical
power of the same frequency in another circuit.
BASIC PRINCIPLE: - the transformer has two coils, which are electrically separated and
magnetically linked through a common magnetic path. When two coils are inductively coupled
and the current in one coil is changed uniformly, an emf (electromagnetic force) is induced in the
other coil. If a closed path is provided at the secondary circuit, this induced emf at the secondary
drives a current.
Figure 31. wiring diagram of power house
2.4.9. COMPONENTS OF POWER AND CONTROL PANEL BOARDS

2.4.9.1. COMPONENTS OF POWER PANEL BOARDS
a). Capacitor Bank: To Improve the power factor of the system & provide Compensation to
reactive power absorbed by inductive loads, reduce the over Loading of the cables, transmission
lines & transformers for the same load to be Handled.
Figure 32. capacitor bank
b). Circuit Breaker: Automatic switching during normal or abnormal condition.
RAYA BREWERY 2017
c) Bus bar: - A bus bar in electrical power distribution refers to thick strips of copper or
aluminum that conducts electricity within a switchboard, distribution board, substation, or other
electrical Apparatus.
d) Fuses: Control circuits are always fuse protected. Fuses are electrical safety devices which
contain a "link" that melts at a pre-determined electrical current. The link melts because of the
heat produced by excessive amounts of current flowing through it. When the fuse link melts, it
opens the circuit and shuts off the current flow.
e) Switches:-there are two fundamental uses for switches. First, switches are used for operator
input to send instructions to the control circuit. Second, switches may be installed on the moving
parts of a machine to provide automatic feedback to the control system.
f). Pushbutton: - The most common switch is the pushbutton. It is also the one that needs the
least description because it is widely used in automotive and electronic equipment applications.
g). Limit Switches:-Limit switches are usually not operator accessible. Instead they are activated
by moving parts on the machine.
h) Indicator Lamps: - The colors are usually red, green, but other colors are also available. Red
lamps are reserved for safety critical indicators (power is on, the machine is running, an access
panel is open, or that a fault has occurred). Green usually indicates safe conditions (power to the
motor is off, brakes are on, etc.).
2.4.9.2. PROGRAMMABLE COMPONENTS CONTROL PANEL
Figure 33. PLC control panel

a) AC to DC converter: - A rectifier is an electrical device that converts alternating current (AC),
which periodically reverses direction, to direct current (DC), which flows in only one direction.
The process is known as rectification. This devise is supply DC voltage for sensor which back to
PLC card.
RAYA BREWERY 2017
Figure 34. AC to DC convertor
B) Profibus (processes filed bus):- DP (decentralized peripheral) is a speed optimized protocol

especially designed for inexpensive communication between DP masters and decentralized field
units, DP slaves.
Figure 35. profibus connection
C).ASI master/slave: As-interface stands for actuator/sensor interface. It is a connecting system

of lowest processes level (I/O level) in automation systems.
D) As-I safety: - is a safety monitor reads the code tables of all safe slaves by means of teach
in function in order to continuously monitor their operation. General network hierarchies of
control panel components
Figure 36. Communication of control panel component
RAYA BREWERY 2017
2.4.10. PROJECT: - CONTROL OF BOILER OPERATION USING PLC
2.4.10.1.1. Introduction
In raya brewery share company 36000 bottles are filled in every hour. However from this some
of the products (bottles) are scarifies or rejects by the case of under fill and unlabeled. By these
cases a huge amount of bottles are rejects. This rejected beer is removed as a waste product. By
this reason the company losses huge amount of many and affects from achieving its objective
and mission of its current performance. In addition to this raya brewery S.C. is a big company
however it has no integrated fire detector with boiler and it cannot use ph sensor, flow sensor and
oxygen sensor to develop their performance and efficiency.
A boiler is a closed vessel which is used to heat up water or other fluids and those heated or
vaporized fluids are then furthered used for different processes.
2.4.10.1.2. Statement of problem

In order to automate a power plant and minimize human intervention, there is a need to develop a
PLC that monitors the plant and helps reduce the errors caused by humans.
2.4.10.1.3. Objective of the problem
2.4.10.1.3.1. General objective
The main objective of industrial boiler automation is to design a convenience and suitable
industrial boiler automation to achieve optimum operating efficiency with high reliability and
low cost
2.4. 10.1.3.2. Specific objective

The specific objective of the project will be:
Controlling boiler before damaging, controlling boiler from hazards
To reduce overall expenditure in terms of wages, wastage of material due to inaccurate
manual work and to reduce the overall time taken for production in industries.
To increase plant production efficiency and accuracy
2.4.10.1.4. Significant of the project

To measure the actual values of different parameters for which the boiler is designed.
In case of operator failure to take remedial action for an upset condition, it protects the
boiler by alarms and trappings.
RAYA BREWERY 2017
2.4.10.1.5. Scope of the project

My project is specified for only seven systems due to the material requirement and time specified
for the project.
Level Control Oxygen control Temperature
Pressure Control Fire detector Control pH monitor
Flow Control control
Area of Expertise: Industrial boiler automation was available on different areas. From these areas
the mains are listed below:
Food processing
Water treatment projects and others which are needs a boiler
2.4.10.2.LITERATURE REVIEW
This section will explain the literature study that is related to the project task. I get the
information from several sources such as books, websites, journals, magazines, and others.
Research on the main steam pressure control system of boilers based on microcontroller PI
control Strategic Technology (IFOST), 2011 6th International Forum on (Volume: 2) on
2224 Aug. 2011at Harbin, Heilongjiang
The main steam pressure control system of boilers has a lot of characteristics, include the large
inertia, the highly delay, and the nonlinear and time-varying, there are many disturbance factors
in its operation and it are hardly to control. In order to solve this situation, this article integrates
the advantages of the microcontroller based Control. Then I entities from this idea I design
industrial boiler automation based on PLC with high efficiency and reliable.
G.F. Gilman, Jerry Gilman (2004) Boiler drum level control, Boiler control systems
engineering: retrieved, May 10, 2014.
This section of the book describes the need of having a boiler drum level controller. It states that:
Drum level must be controlled to the limit s specified by the boiler manufacturer. If the drum
level doesnt stay within these limits there may be water carry over. If the level exceeds the
limits, boiler water carry over in to super heater or the turbine may cause damage resulting in
extensive maintenance costs or outages of either the turbine or the boiler.
David Lindsey (2000) Chapter 7 steam temperature control Power-plant control and
instrumentation: the control of boilers and HRSG systems (page 135-151) retrieved, May
18, 2014.
RAYA BREWERY 2017
Here from this part of the book I have obtained some information about the boiler steam
temperature control. As stated in the book the rate at which heat is transferred to the fluid in the
tube banks of a boiler will depend on the rate of heat input from the fuel or exhaust from the gas
turbine. This heat will be used to convert water to steam and then to increase the temperature of
the steam in the super heat states. So indirectly controlling the fuel valve means controlling the
temperature of the steam. The boiler temperature will also be affected by the pattern in which the
burners are fired, since some banks of tubes pick up heat by direct radiation from the burners. In
both types of plants the temperature of the steam will also be affected by the flow of fluid within
the tubes, and by the way in which the hot gases circulate within the boiler.
The temperature of the steam may vary based on the load on the boiler and the load of the plants
may vary due to many different factors. So to compensate the changes with the desired process
values or set points mostly plc controllers are employed. The plc controller traces the change in
set point and adjusts the process value.
2.4.10.3. METHODOLOGY
2.4.10.3.1. Introduction
In this section we will show details of our system designs. The system designs include the
hardware description, software designs that are based on the SIMENSE SIMATIC S7-200
software, block diagram of the system and flow charts. Therefore I have developed the industrial
boiler automation using drum level control, steam header over pressure relief control, Boiler
temperature , and feed-water PH control systems using PLC by configuring (programming) it to
the desired operation.
These systems are classified in to 2 sub categories. The boiler protection control system and the
boiler performance enhancement control system.
In the boiler protection control system the drum level control, steam header over pressure relief
control and fire detector systems are included. And the boiler performance enhancement control
system includes the boiler temperature; feed water pH control and oxygen control systems.
2.4.10.3.2. Components of the system

Input device to the PLC
The input device are such as Temperature sensor, Oxygen sensor, Pressure sensor, Flow sensor,
Level sensor, Fire detector and pH sensor
RAYA BREWERY 2017
The output device from the PLC

The output device also such as Buzzers, Motor pumps, Dose pump motor, Solenoid Valves,
Check valve, Safety exhaust valve and Mixer motors.
The controller
SIMENSE SIMATIC S7-200 PLC software
2.4.10.3.3. System model the overall block diagram of the system will be:
Figure 37. Block diagram of the system
INPUT SYSTEM COMPONENTS

1. Switches
Switches are the basic components of PLC. Two types of switches are available in plc.
I. Digital switch (ON/OFF).
II. Analog switches (continuous varying).
2. Timer
In my project I used one type of timer for activate of valves and deactivate the buzzer.
I. On delay countdown starts when supply is ON and timer is ON when countdown
becomes zero. If timer is made OFF output is OFF.
3. Sensors
An electrical signal is sent from the sensor to the PLC indicating the condition (ON Resistance
Thermometer Detector /OFF) of the sensors contacts. The following types of sensors are used for
my project.
A. Temperature sensor
RAYA BREWERY 2017
This type of sensor is used to sense the temperature value of the industrial boiler automation by
compare and contrast the set point with the measured value of the system. As I have to masseur
high temperature for the furnace so I use 3 wire PT100 temperature sensors. It has very high
temperature range about from -200 to 8500c.
B. Pressure sensor
In my project I select strain gauge pressure sensor which will placed at the top of the boiler and
will continuously sense the pressure in entire to the plant. Its pressure range is from 0 to 10 Bar.
C. Level sensor
All boilers require feed-water flow control to make up for the steam that leaves the boiler. The
water level in the drum must be also maintained to provide responsive and stable control of the
steam flow, as well as to prevent equipment damage.
Control system for reservoir tank: this tank plays main role to optimize an efficient control of
boiler automation. This tank is used to neutralize the pH of the water and it is the main source for
the boiler tank. So in order to full fill the desired specifications of the boiler we need to control
the reservoir tank pH level and level of the water. We have minimum level sensor then if the
level of water reach at the LTL the sensor will OFF then the PLC will be close automatically
stop the feeder water pump to the boiler and also the buzzer will ON to notify for the operator.
Figure Figure 38. Water and fuel level control system

D. PH sensor
The main objective of pH sensor is to detect the water whether it has an acidity or base content.
Because a specified or limited amount of acid and base is necessary for every industry. In this
case the level senses the value of acidity and base content.
PH control system: in this case our main agenda is to maintain pH factor of water by controlling
the addition of base or acid in the main process tank through acid &base dose pump.
RAYA BREWERY 2017
Figure Figure 39. pH sensor control block diagram
E. Fire detector
Fire detectors are designed to respond at an early stage to one more of the three major
characteristics of combustion heat, smoke or flame. No single type of detector is suitable for all
types of premises or fires. Detectors should be chosen for the best response to the effects of fires.
In my project I will be use heat detector, flame detector and smock detector for the fire
protection method.
Smock detector: - A smoke detector is a device that detects smoke, typically as an

indicator of fire.
Flame detector: - A flame detector is a sensor design to detect and respond to the
presence of the flame or the fire. Response to a detected flame depends on the installation
but can sounding an alarm.
Heat detector: - Heat detectors respond to the temperature rise associated with a fire. A
fixed temperature heat detector is designed to operate when the temperature at the
detector exceeds a predetermined value.
F. Oxygen sensor: - is used to sense or manage the excess of the amount of oxygen content in
the Furness which is used to compare and contrast with the set point for highly efficient
FINAL INTERNSHIP REPORT Pre.By. Berhe Dargo (industrial control engineer Page 32
RAYA BREWERY 2017
combustion. In my project I use oxygen analyzers for improved measurement accuracy and
repeatability; users are also demanding analyzers that require a minimum of maintenance
and calibration.
G. Flow sensor: - is used to sense the travelling or flowing of the fluid from the environment
to the main system and also regarded as fast loops that respond to change quickly.
Figure 40. Block diagram of flow control system
OUTPUT SYSTEM COMPONENT
Water and fuel pump motor
Water pump is used to feed water to the boiler tank from the reservoir tank, it is one of the most
important component, it starts automatically whenever there is water below the threshold level
and this will keep the boilers water level always above the threshold level.
Fuel pump is the main part of the boiler system. The fuel pump makes fuel to reach the burner
so that required heat energy to produce steam is provided. It also required providing a constant
fuel supply to the burner. Physically the water and fuel pump are more or less similar.
RAYA BREWERY 2017
Dosing pump: - is small, positive displacement pump. It designed to pump very precise flow
rate of chemical or substance into either a water, steam or gas flow. A dosing pump will deliver
this precise flow rate of chemical or other product by a number of different methods but it
generally involves drawing a measured amount into chamber and injecting this volume of
chemical into the pipe or tank being dosed.
Figure 41. Overview of dosing chemicals
Solenoid valves: - is an electromechanical valve for use with liquid or gas. The valve is
controlled by an electric current through a solenoid: Solenoid actuated valves provide for
automatic open close valve positioning. Two solenoids can be used to provide for both opening
and closing by applying power to the appropriate solenoid
Buzzer:-In my project I use the electromechanical type of buzzer due to their specifications and
futures. Low frequency tone (2 kHz), Suitable for automatic radial taping machine(15mm-
pitch)and Sound pressure:70dBA,10cm min.[at 2kHz, 5V0-P rectangular wave,
Relays:-is a simple electromechanical switch made up of an electromagnet and a set of contacts.

Relays are found hidden in all sorts of devices. Relays are used where it is necessary to control a
circuit by a low-power signal (with complete electrical isolation between control and controlled
circuits), or where several circuits must be controlled by one signal.
RAYA BREWERY 2017
Mixer motor: - is a unit operation that involves manipulation of a heterogeneous physical system
with the intent to make it more homogeneous. Mixing is performed to allow heat and/or mass
transfer to occur between one or more steams, components or phases.
Figure 42. Typical mixer motor
Damper: - is a valve or plate that stops or regulates the flow of air inside a duct, chimney. A
damper may be used to cut off central air conditioning (heating or cooling) to an unused
room, or to regulate it for room-by-room temperature and climate control. Automatic
dampers are used to regulate airflow constantly and are operated by electric or pneumatic
motors, in turn controlled by an oxygen sensor or building automation system..
Check Valve: - A check valve, clack valve, non-return valve or one way valve is a valve that
normally allows gas to flow through it in only one direction. Check valves are two port
valves, meaning they have two openings in the body, one for gas to enter and other for gas to
leave..
CO2 Extinguisher: - Carbon dioxide is a type of clean agent that pushes out oxygen and
replaces it. The fire easily dies out when carbon dioxide displaces oxygen. A clean agent in
fire extinguishers is something that does not leave residues on electrical equipment. It also
prevents fire from scattering further because it blocks out a chain reaction of chemicals
starting from the zone where the fire had originated.
RAYA BREWERY 2017
2.4.10.3.5. Over all view of the system
Figure 43. Industrial boiler process block diagram
Flow chart of the system

In this part we will show how work the sensors, valves, pumps and other equipments
diagrammatically. Then we sketch each flow chart for each process and lastly combined in one
big flow chart.
RAYA BREWERY 2017
RAYA BREWERY 2017
Figure 44. General flow chart of the system
2.4.10.4. CONCLUSION AND RECOMMENDATION

2.4.10. 4.1. Conclusion
In Boilers automation is one of the main ways to increase efficiency of raya brewery s.c. It
reduces fuel consumption and provide trouble-free running. The most important aspect of most
production plants is the boiler control.
The Paper has furnished itself to study the integral parts of the entire process involved on the
boiler system..
RAYA BREWERY 2017
2.4.10.4.2. Recommendation
In this project automatic PLC based controlled solution for industrial boiler automation has been
introduced. This is dealing only to 7 specific systems to control automatically using PLC but this
is may not be enough to control the entire all the industrial boiler components and to make the
industries profitable and to have system components good span life. Therefore to operate our
industrial boiler automatically and to control all component of industrial boiler our future work is
to control all the appliances of the boiler, by using appropriate analog and digital sensors.
2.5. PROCEDURES I USED WHILE WORKING

Before executing any electrical equipment maintenance or a new installation i should design safe
procedures that provide me working guidelines for best work practices, following these
guidelines when performing maintenance and service on electrical equipment or facility
electrical systems will significantly reduce the likelihood of electrical accidents that can result in
fires, injuries and material damage.
I have been oriented with the responsibility of my job by communicating with the company
electrician supervisor and company workers (electrical staff workers). Additionally I have been
fulfilled my responsibility by referring my note books, manuals and accessing internet. The
courses which i have been taking in campus are essential to execute my job. Generally, i have
been oriented with the responsibilities of my job by interrelating with electrician supervisor and
staff workers and by organizing the knowledge which i have been got from campus.
RAYA BREWERY 2017
2.6. PERFORMANCE OF WORK

While I was in the company, i have been working cooperatively with the company workers and
my supervisor. In the first month my practical performance was a little bit weak. Then i tried to
improve my personal performance of work by asking help to the staff workers of the section and
my company supervisor in the remaining months. Generally, I can say I was good in
understanding the manuals and what they told me to follow and doing similar task alone.
2.7. CHALLENGES WE HAVE BEEN FACED

During my internship period I have been faced some problems. The company is a new company
as a result it has not damaged part to repair or replace then I have to see the whole process
visually. Another challenge that we have been faced during my internship period was working
with PLC or auto machine control lack of deep knowledge limits me from participating highly.
2.8. MEASURES WE HAVE BEEN TAKEN TO SOLVE THE CHALLENGES

I have taken some measure to overcome the challenges or problems that I have been faced during
my internship period. I tried to solve the challenge with PLC by asking other PLC technicians. I
also tried to study the course from internet, books and manuals.
RAYA BREWERY 2017
CH APTER THREE
3. OVERALL BENEFITS GAINED FROM OUR INTERNSHIP
3.0. INTRODUCTION
Really this internship program overcome the problem of undergraduate student who havent any
knowledge that they inter their first work place, we are actually the luckiest of this students. We
get some benefit beside which we didnt if we spent those four months in the class. During the
internship period, I have gained benefits which helped me to explore my Skills, qualities,
abilities and scope of my theoretical knowledge. It also gives me the opportunity to Gain Hands-
on experience of working which provides me an outstanding opportunity to apply what I have
learned in the classroom to a real-life situation and strengthen my professional work habit during
the internship period I have developed the following qualities to succeed in my daily activities
3.1. PRACTICAL SKILL

During the intern the most beneficiary thing is that upgrading of practical knowledge that we
earned their theoretical in the class. Most of the courses that we had earned theoretically ar
e highly applicable in what we have been working in, and so we have got a chance to relate the
theory with practical knowledge. We almost saw the practical aspects of the courses and their
application in real work. The practical skills that we gained during the intern are maintaining and
operate the machines, installed the new sensor and install the wire of the power line, etc
3.2. UPGRADING THEORETICAL KNOWLEDGE

The contribution of the internship program is not only for practical also it upgrades our
theoretical knowledge. And it increases the ability to apply systematic design procedure to open
ended problem. And how to analyses something technically. So it upgrades our theoretical
knowledge the same as the practical one. Also Internship memorizes the important conceptual
RAYA BREWERY 2017
theoretical parts that have learned. Among the important ones that the internship upgrades our
theoretical parts includes:
The operation of different electric devices like transformer, contactor, generator and motor.
Learn more about various courses especially on machine design, material selection and
maintenance.
Familiar and understand about the programming logic controller (PLC) architecture,
arithmetic calculations, conditional testing, program operation and I/O device and their
techniques.
3.3. INTERPERSONAL COMMUNICATION SKILL

Most interesting part of the internship was the interpersonal communication and teamwork skills
between me and the company technique staff members. Regardless of their personal behavior, i
have been learning how to work with coworkers of all ages, communicate with supervisors
openly When one spare part (electrical machinery) failed all staff workers participate to solve the
problem; as a result i have been improved a go
3.4. TEAM PLAYING SKILLS

Among the most important skills that we developed during the intern are our communication and
working together /team sprit/ skill. In our company all of the workers are sociable. Most of the
time we discuss about the works and other related issues wisely. During the internship there were
many job responsibilities that we have been done with the workers. So we have learned the
following points from them:-
Listening the idea of others whatever it is.
Be patient and wise and respect fullness of the voice of others.
Open minded to other point of view.
Able to share information freely.
RAYA BREWERY 2017
3.5. LEADERSHIP SKILLS

Leadership is a skill to guide, control and monitor peoples. For effective leadership we
understood that personal values like confidence, effective communication and devotion are very
important role. We have actually observed the method of controlling the working time and
amount of work done by each worker so that the work proceeds according to the work plan. We
have seen how each worker is controlled and organized to perform its day to day activities.
3.6. WORK ETHICS
We have been guided and obeyed by the rule and regulation of the company. Some of the work
ethics include; Punctuality, Office disciplines, Reliability, Honesty and Cooperation. From this
perspective, weve gained a valuable lesson that transparency and carefulness are two very
important work ethics one needs to abide and live by these statements of intended conduct are
expected of every member (permanent members, associate members, contract members and
student members) of the Raya brewery s.c.
3.7. ENTREPRENEURSHIP SKILL:

Emphasizing the growth of entrepreneurship is a basis for improving the social and economic
capability of the country. We had a wide range of entrepreneur skills from above skills including
personal traits and management skills.
The ability to manage time and labor (both myself and others) successfully.
The ability to work both as part of a team and independently.
Able to plan, coordinate and organized effectively.
How to improve self-motivation and discipline
3.8. INTERPERSONAL SKILLS
The ability to speak clearly and confidentially.
The ability to listen and understand others (co-workers).
The ability giving a solution for a problem and the motivations,
RAYA BREWERY 2017
CHAPTER FOUR
4. CONCLUSION AND RECOMMENDATION
4.1. CONCLUSION
Raya Brewery Share Company is one of the new brewery production plants occupying an area of
18.5 hectares. The main raw materials used for beer production are raw materials like, water,
hops and yeast; other inputs such as filter aids, different chemicals for cleaning, sanitation,
disinfecting, water treatment, cooling, packaging materials, and utilities. There four main section
of Raya brewery Share Company. These are brew house, filtration and fermentation, packaging
and utility. The operations which are performed in beer house, fermentation and filtration are
controlled by SCAD-PLC. When the problem is faced there is an alarm to tell the problem to the
operators. This is the main strength of the company. At the end of fermentation carbon dioxide is
recovered because it uses for filling and filtration. Utility it is the back bone of the company w/c
is the sources of steam, process & service water, glycol and purified CO2 those have significant
impact on the production process. And also types of motors, controlling systems and sensors
used in the company.
Induction motor (Asynchronous): Induction motors are the most common motors used for
various equipments in industry, which is run vary with time.
Synchronous motor: A synchronous motor is an AC motor, which runs at constant speed
fixed by frequency of the system.
Servo drive motors: they are mainly used because of minimal space requirement, flexible, a
PID is a feedback controller that is widely used in many control applications, and robust
design, and wide range of combinations with low noise operation.
RAYA BREWERY 2017
A PLC is a microprocessor-based controller with multiple inputs and outputs. It uses a

programmable memory to store instructions and carry out functions to control machines and
processes.
SCADA systems are used to monitor and control a plant or equipment in industries such as
telecommunications, water and waste control, energy, oil and gas refining and transportation
Types of sensors used in the company are like: Inductive sensor, temperature sensor, pressure
sensor, level sensor, photo cell sensor, proximity sensor and so on. Therefore, we have
conclude that the internship program is the best and mandatory program for engineering
students to enhance their theoretical knowledge, practical skill, leadership skill,
entrepreneurship skill, creativity, team playing skill and so on.
RAYA BREWERY 2017
4.2 RECOMMENDATION
Raya brewery Share Company is a big company planted to produce a high quality beer and draft.
But, I have seen some problems in the company such as:
The company is a big but it does not have full/empty create inspector in packer and
sidewall camera in the EBI.
The company has not recycle conveyor to recycle these rejected unlabeled bottles to
labeler machine.
The company hasnt electrical workshop to maintain the damaged equipment.
There is not enough spare part for most equipment. The supply and marketing department
must give a great attention on the supplying of spare parts.
Row material such as malt is not produce in Ethiopia its highest quantity. As a result the
company enters to high cost because of transportation. So the company must motivate to
the farmers to produce the malt in Ethiopia to mutually benefit.
For the university
The internship period plays a great role to relate students theoretical knowledge with practical
skill. But there are some problems or challenges faced to students. Some companies have no
understanding about internship.
Thus, my recommendation for the internship period is first universities must introduce
about the aim of internship to all companies of the country in order to recognize what are
the duties and rights of the student.
Most companies of Ethiopia are working with a PLC controller so the university
lecturers should give a great attention for this course before the internship program. And
the campus must give all the prerequisite courses before students go for internship.
RAYA BREWERY 2017
REFERENCE
1. www.krones.com.
2. Boyer, Stuart, A. SCADA: Supervisory Control and Data Acquisition, Instrument Society of
America, Research Triangle, NC. 1993
3. MEL 334 Low Cost Automation PROGRAMMABLE LOGIC CONTROLLER volume2.
4. Mykuz, Brew science books and company manuals.
5. Technology Brewing and malting, Wolfgang Kunze, International Edition, 1999.
6. www.onsemi.com
7. BL.Theraja A Text Book of Electrical Technology.
8. www.em.co.za
9. Rockwell Automation SCADA System Selection guide Allen-Bradley, Publication AG-2.1.
1998.
10. Knight.U.The Power System and its Operational and Control Infrastructure in emergencies
from contingency planning to crisis management.
11. Analysis of Fault-Tolerant systems, IEEE transactions on Computers, vol.38, No.6, 1989.
12. Hillenbrand, Cary, Expert Three, Technical expert specializing in the planning and design of
SCADA based and Distributed control system.
13. https://ethiopia observatory.com
14. https://WWW.etyellow pages.com
RAYA BREWERY 2017
Appendix
Table 2.Input/output assignments of the project
No. Symbol Description

1 I0.0 Start push button
2 I0.1 Stop push button
3 I0.2 Fuel minimum level sensor
4 I0.3 Reservoir water tank level sensor
5 I0.4 Upper thresher level of boiler tank
6 I0.5 Critical maximum level of boiler tank
7 I0.6 Flame sensor
8 I0.7 Heat sensor
9 I1.0 Smock sensor
10 SMB 28 (>400) Temperature sensor
11 SMB 28 (>8) Pressure sensor
12 SMB 28 (<7) Acid pH sensor
13 SMB 28 (>7) Base pH sensor
14 SMB 28 (=7) Neutral pH sensor
15 SMB 29 (=28) Flow sensor
16 SMB 29 (<8) Oxygen sensor
17 Q0.0 Internal coil
18 Q0.0 Auxiliary coil
19 Q0.1 Buzzer for low level of fuel tank
20 Q0.2 Fuel pump
21 Q0.3 Fuel valve
22 Q0.4 Dose acid
23 Q0.5 Dose base
24 Q0.6 Mixer
25 Q0.7 Pump water
26 Q1.0 Water valve
27 Q1.2 Damper
28 Q1.3 Stop fuel pump
29 Q1.4 Stop fuel valve
30 Q1.6 Buzzer for fire
31 Q1.7 Check valve
32 Q2.0 Buzzer for low level of reservoir tanker

B BBBBBB BBBBBB BBBBBB BBBBBB

Uploaded by

Copyright:

Available Formats

B BBBBBB BBBBBB BBBBBB BBBBBB

Uploaded by

Document Information

Original Description:

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

B BBBBBB BBBBBB BBBBBB BBBBBB

Uploaded by

Copyright:

Available Formats

RAYA BREWERY 2017

FINAL INTERNSHIP REPORT

Submission date Submitted to

2.4.8. POWER DISTRIBUTION OF A COMPANY AND COMPONENTS ................................... 23

CCT ___________________________________________cylindrical canonical tank

CEO____________________________________________ Chief executive Organization

DG1____________________________________________ diagram generator-1

DG2 ___________________________________________diagram generator-2

EBI_____________________________________________ empty bottle inspection

EEPCO________________________________________ Ethiopia electric power corporation

FBI_______________________________________________ full bottle inspection

PLC_______________________________________________ programmable logic control

PID_______________________________________________ proportional integration and derivative

S.C_______________________________________________ Share Company

SCADA__________________________________________ Supervisor control and data acquisition system

[Type text] Page 1

1.2 MAIN PRODUCTS OR SERVIC OF THE COMPANY

High quality beer

1.4 RAW MATERIALS REQUIREMENT FOR THE COMPANY

Production Procurement Project Finance

Figure 1. over all organization of the company

OVER ALL INTERNSHIP EXPERIENCE

2.0. GETTING IN TO THE COMPANY

2.1. WHY DO YOU SELECT THIS COMPANY?

2.2. SECTION OF THE COMPANY I HAVE BEEN WORKED

Figure 2. Beer manufacturing process

2.3.1 PROCESS DISCRIPITION OF THESE SECTIONS

Figure 3.Classic mill

Figure 4: wart kettle

Figure 5. Production process of bottled area

Figure 6.De-palletizer machine

Figure 7. Unpacker machine

Figure 8. Bottle washer

The bottles to be cleaned passes through the following stages

Figure 9. Bottle washer

Figure 10. EBI AND VHI

Figure 11. Gap detection

Figure 12. Optical detection

Figure 13.Mouth and base

Figure 14.base and Residual liquid inspection

Figure 15.Bottle filling machine with capper

Figure 16. pasteurizer with its pump motors

Figure 17. Induction motor in pasteurizer

Figure 18. Labeler

Figure 20. Palletize with control panel

Figure 21. keg line

Figure 22. Keg washer

steaming, venting & CO2 pressurizing and filling of drought beer.

FigureFigure 23. Production process drought beer

Figure 24. types of controlling systems

1. Concept of Relay Function

Figure 25. CONTROL SYSTEM OF PID

3. Programmable Logic Controller (PLC):

Figure 26. PLC

The most essential components are:

Figure 27. configuration of I/O module to PLC

Table 1 application and its signal flow of plc

Application of PLC in a company