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WOLDIA UNIVERSITY

WOLDIA INSTITUTE OF TECHNOLOGY

SCHOOL OF ELECTRICAL AND COMPUTER ENGINEERING

STREAM OF INDUSTRIAL CONTROL ENGINEERING

NAME OF HOSTING COMPANY: - MOGLE BOTTLED WATER


MANUFACTURING COMPANY

INTERNSHIP REPORT FROM NOVEMBER 2022 G.C – FEBRUARY 2023


G.C

NAME: AKAWUK GEREMU

ID NO: WDU103955

Advisor: MR. ABEBUAL

Submitted To:

School of Electrical and Computer Engineering, Woldia University

March 2023

Woldia, Ethiopia
INTERNSHIP REPORT
DECLARATION
I am fifth year Electrical and Computer Engineering student. Here i declare that this
final evaluation report has been submitted to woldia university institute of technology
in partial fulfillment of the requirements of Engineering Internship program in School
of Electrical and Computer Engineering. The objective of this report is to explain what
I did and learned that in my practical skills, theoretical knowledge, inter personal
communication skills, team working skills, leadership skills, work ethics and
entrepreneurship skills during internship period in the Mogle (ONE) bottled Water
under the supervisor of Mr. Oli. In my hosting company mogle (ONE) bottle water
manufacture Company I spent four consecutive months for the internship program.
This report is my original work, has not been presented in this or any other universities
or companies and all sources of materials used for the report have been fully
acknowledged

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EXCUTIVE SUMMARY
This particular paper is concerned with the functions i accomplished in four months
of internship period and the overall functions, process, products, organizational
structure and work flow of the industry that i have been worked in. The functions
that i accomplished which are included in this paper are observation of the
different kinds of processes, machines and products, the problems are identified
after observation, solutions and recommendations the main problems. Also
challenges i faced during this internship period and different kinds of benefits that i
gained from this program are included. This report generally provides an insight
into my role in the company, an overview about mogle bottled water manufacturing
Company. And also the skills i developed and experience i obtained during stay in
mogle bottled Water manufacturing Company for internship program. Mogle
bottled water manufacturing Company has been a great experience that i learned a
lot from it. I developed my theoretical skill to practical skill. This report has five
chapters. The first chapter discusses about the background of mogle bottled Water
manufacturing Company. And the second chapter deals with overall experience of
internship. Chapter three covers the challenges and experience of internship.
Chapter four, deals on the project contribution of design and simulation of filled
bottled inspection and the fifth chapter describe conclusion and recommendation
for mogle bottled Water manufacturing company. For this report i have given brief
review of background of mogle bottled Water manufacturing company, including its
vision, mission and objectives, organization structures, production processes. Next,
i explained all internship experiences including, how i get in to the company, work
section, challenges i faced and measures taken and then benefits got in the
internship including theoretical and practical skills, team playing skills,
interpersonal skill and leadership are included. After all these topics i have also
included conclusions and recommendation for improvement of works in the
company certain feature recommended for the project.

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Table of Contents
DECLARATION.............................................................................................................I
EXCUTIVE SUMMARY...............................................................................................II
List Of Figures...............................................................................................................VI
List Of Tables...........................................................................................................VII
List Of Acronym.................................................................................................VIII
CHAPTER ONE..............................................................................................................1
1. BACKGROUND OF MOGLE BOTTLED WATER.............................................1
1.1. Brief History Of Mogle Bottle Water Manufacturing Company......................1
1.1.1 Location.....................................................................................................2
1.2 Vision And Mission Of The Company.............................................................2
1.2.1 Vision........................................................................................................2
1.2.2 Mission......................................................................................................2
1.3 Objective Of The Company..............................................................................2
1.4. The Main Product Of One WaterFactory.........................................................3
1.5. The Main Customers Or End Users Of Products..............................................3
1.6. Source Of Raw Materials..................................................................................4
1.7. Organizational Structure of The Company.......................................................4
CHAPTER TWO.............................................................................................................5
2. OVERALL INTERNSHIP EXPERIENCE.............................................................5
1.4. Way I Get The Company..................................................................................5
1.4. Section Of The Company That I Have Been Worked In..................................5
2.3. Work Flow In The Section................................................................................6
2.3.1. Water Treatment Process...........................................................................6
2.3.2. Bottle Water Production Process Steps...................................................11
Air Compressor......................................................................................................11
2.4. Work Piece or Work Task I Have Been Executing........................................16
2.4.1 Starting Method of Motor........................................................................17
2.4.2 Direct On-Line (DOL).............................................................................17
2.4.3 Star Delta Starter Method........................................................................18
2.4.4 Forward/Reverse Starter Method............................................................20
2.5 Methods and Procedures.................................................................................20
2.5.1 Methods...................................................................................................20
2.5.2 Procedures...............................................................................................20
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2.6 How Good I Have Been in Performing My Work Tasks...............................21
2.7 Challenges I Have Being Faced......................................................................21
2.8 Measurement I Have Taken to Overcome These Challenges.........................21
CHAPTER THREE.......................................................................................................22
3 OVERALL BENEFITS GAINED FROM INTERNSHIP....................................22
3.1. In Terms Of Improving Practical Skill...........................................................22
3.2. In Terms of Upgrading Theoretical Knowledge.............................................23
3.3. In Terms of Improving Interpersonal Communication Skill.......................23
3.4. In Terms of Improving Team Work Skill...................................................24
3.5. In Terms Of Improving Leadership Skills..................................................24
3.6. Understanding Work Ethics........................................................................25
3.7. In Terms of Entrepreneurship Skills...............................................................26
CHAPTER FOUR.........................................................................................................28
4. PROBLEMS IDENTIFIED AND SOLUTION PROPOSED...............................28
4.1. Problems observed..........................................................................................28
4.2. Proposed Solution...........................................................................................28
PROJECT SELECTED.................................................................................................28
4.3. Water Tank Level Controller by using PLC...................................................28
Abstract..........................................................................................................................28
4.3.1. Introduction.............................................................................................29
4.3.2. Problem Statement of the projects...........................................................29
4.4 Objective of the project...................................................................................29
4.4.1 General objective.....................................................................................29
4.4.2. Specific Objectives..................................................................................29
4.5 Significance of the project..............................................................................30
4.6 Scope of the project........................................................................................30
4.7 PLC ( Programmable Logic Control)............................................................30
4.8. Methodology...................................................................................................31
4.9. Material Requirements of the Project.............................................................32
4.10. Result and Discussion of PLC Simulation..................................................33
CHAPTER FIVE...........................................................................................................37
5. CONCLUSION AND RECOMMENDATIONS..................................................37
5.1. CONCLUSION...........................................................................................37
5.2. RECOMMENDATION..............................................................................37
REFERENCES..........................................................................................................39
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List Of Figures
Figure 1 Mogle bottle water manufacturing company....................................................1
Figure 2 The main product of mogle bottle water manufacturing company...................3
Figure 3 Organizational structure of the mogle bottled one water manufacturing..........4
Figure 4 Process flow chart of water treatment line........................................................7
Figure 5 Sand filter tanker...............................................................................................8
Figure 6 Carbon filter and activated carbon....................................................................9
Figure 7 Micro filter......................................................................................................10
Figure 8 Reverse osmosis membrane............................................................................10
Figure 9 Blowing machine............................................................................................12
Figure 10 Filling machine..............................................................................................14
Figure 11 Capping machine Date coder........................................................................14
Figure 12 Labeling machine..........................................................................................16
Figure 13 Power and control circuit of direct online.....................................................18
Figure 14 Power and control circuit of star delta starting method of motor.................19
Figure 15 Power and control circuit of forward/reverse starting method of motor.......20
Figure 17 Flowchart.......................................................................................................31
Figure 18 flowchart of water level control....................................................................32
Figure 19 Reservoirs drum level control ladder diagram..............................................35

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List Of Tables
Table 1 Level of boiler drum control LAD symbol description....................................36

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List Of Acronym
CIP Cleaning Internal part

CPU Central Processing Unit

DC Direct Current

EPA Environmental Protection Agency

FBI Full Bottle Inspection

HR Human Resource

LCD Liquid crystal display

LED Light emitted display

PLC Programmable Logic Circuit

RO Reverse Osmosis

WHO World Health Organization

UV Ultraviolet

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CHAPTER ONE
1. BACKGROUND OF MOGLE BOTTLED WATER
MANUFACTURING COMPANY
1.1. Brief History Of Mogle Bottle Water Manufacturing Company
Back grounding of the hosting company mogle bottled water manufacturing is one of
the major businesses’ units of Abbahawa trading PLC under the name one water. One
natural purified water is a refined and filtered water. One water began production in
2015 G.C with the aim of accomplishing the out most quality level in the
manufacturing of its products while preserving the organic substance in its packaged
spring water

Figure 1 Mogle bottle water manufacturing company

Mogle bottle water manufacturing company is located in Oromia, at Sebeta Town


around 20KM distance from Addis Ababa. It rests on a vast 75000-meter square plot
of land with built up area of 35000-meter square and having six production line with a
manufacturing capacity of 120,000 bottle per hour and the initial venture cost was
upward of 3.3 billion birrs today one water has more than 650 employer and has

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created job opportunities for over 1000 individuals working in the firm categorized under
six major sections.
these are: -

 HR manager.

 Admin staff.

 Marketing staff.

 Technique section.

 Quality and sanitation.

 Production section.

1.1.1 Location
 One purified water and soft drink is located in Oromia, at Sebata Town, 07 Kebele.
 Website: onewater,com

 P.O.Box 2079 A.A

1.2 Vision And Mission of The Company


1.2.1 Vision
To be the leading bottled water manufacturer in Ethiopia and one of the recognized brands in
the world.

1.2.2 Mission
We are devoted to surpassing our customers‟ expectations by providing products and
services of the highest standard bottled water. Focus area of one water manufacturing,
Capacity Expansion Growth.
 Increase Revenue generation.

 Enhancing Customer Satisfaction.

 Fulfilling Regulatory Compliance.

 Engagement with a stakeholder.


 Employer happiness.

1.3 Objective Of the Company


 The objective of the company is to produce and sell purified drink water and soft drink
related products profitably.

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 The company strives to produce quality products and keep its reputation by maintaining
the implemented management system.
 To produce and deliver consistent high quality of (ONE) Mogle water at regional and
international markets whilst behaving in a responsible manner.

1.4. The Main Product Of One Water Factory


 0.35L bottled water.

 0.6L bottled water.

 1L bottled water.

 1.5L bottled water.

 2L bottled water.

 20L bottled water.

Figure 2 The main product of mogle bottle water manufacturing company

1.5. The Main Customers or End Users of Products


 Non- Governmental Aid Organization.

 Governmental office.

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 Super markets.

 Shops.

 The society.

 Hotels.

1.6. Source Of Raw Materials


The main source of raw material for the company is water and performs which is found from
the local manufacturer and outside the country.

1.7. Organizational Structure of The Company

Figure 3 Organizational structure of the mogle bottled one water manufacturing

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CHAPTER TWO

2. OVERALL INTERNSHIP EXPERIENCE


1.4. Way, I Get the Company
The internship program is arranged by Woldia University faculty of technology when
I am fifth year at the first semester. First, I give letter provided by school of Electrical
and Computer Engineering to the Mogle bottle water manufacture company, after
completion of the fourth year. Then I was allowed to enter the company as per the
curriculum structure of Woldia University School of Electrical and Computer
Engineering. As I have been arrived to the company, firstly i have introduced myself
to the general Electrical technical director of the company. At the first day I visited
the company as a whole and start my original work by communicating with advisor
from the company to work in electrical department of technical manager which sit at
Sebata. In the company under technical manager in Electrical department, I have
generally seen how to control the product, maintain instrument, installing certain
machine and services. Generally, I have been gotten so many experiences like
practical scale up, upgrading theoretical skills, develop the habit of the
communicating, and adjust myself with industrial atmosphere and leadership ability
from the internship program.

1.4. Section Of the Company That I Have Been Worked In


The factory has several sections which has direct link with the aim of my internship.
My first and second week was almost full of introduction and I have visited all
sections of the factory. In that time, I was tried to pick out the parts of the company
that I should spend my four months. After visited the company, I have introduced
myself to the factory workers. Then gradually I have updated myself to the production
process of the company and become familiar with the working conditions and
environment of the company. I have classified my four months and prepared a
schedule to observe different sections of the company. Generally, I have spent my
four months internship program in the following section of the company:
 Water treatment.

 Blow mold machine.

 Filler machine.

 Shrink packer machine.

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 Laboratory room (physicochemical).

 Starting method of motor and other installation (work shop).

2.3. Work Flow in The Section


The chemists check the quality of preform, cap and body label in the physicochemical
laboratory by measuring the mass of the preform and cap. In addition, they also check
whether the body labels are properly printed and contain all the information needed.
The chemists take sample from the pure water tank and perform physicochemical
analysis every 30 minute. The operators of the treatment section control the
purification process starting from the sand filter up to UV light and perform CIP
(cleaning internal part) according to cleaning and sanitation schedule and procedure.
After they perform CIP, the chemists take sample and check the PH. The preforms are
stored in the storage room and only preforms required for immediate use are kept in
the bottle blowing area. Preforms arrive at the blowing machine with cartons inside
covered with poly bag and opened immediately before putting it to the preform
conveyor to avoid contamination. Touching preforms with bare hand is not allowed,
so if it is necessary to touch preforms on the conveyor the operators always did this
with glove. The operators remove deformed and improperly blown bottles before
going to the filling machine. The blowing machine operators were always alert to
check the quality of the blown bottle. The blowing machine was cleaned and polished
regularly. Operators of the filling machine always cover their mouth and nose because
direct breathing, sneezing and coughing towards the filling machine is avoided. The
cap conveyor was closed and cleaned regularly. The light inspection personnel’s
check the purity of the water, over fill/under fill, accurate capping and proper blowing
of bottles, proper labeling and date coding of bottles. Operators of the labeling
machine check whether the labels are putted on each and every bottle. The products
are stored according to their production date.

2.3.1. Water Treatment Process


Water treatment is any process that makes water more acceptable for specific end use.
The end use may be for drinking, industrial water supply, irrigation, river flow
maintenance, water recreation or many other ends uses, including being safely
returned to the environment. Water treatment removes contaminants and undesirable
components or reduces their concentration so that the water becomes fit for its desired

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end-use. But in One natural purified water facility the end-use is for drinking purpose.
The procedures being used to purify the raw groundwater here at ONE natural
purified water are summarized as below. The choice of these unit operations is
depended on the quality of raw water available, the cost of treatment process and the
quality standard expected of the processed water with capturing particulate matter,
inorganic and organic compounds. These procedures make sure that, the groundwater
being processed will have no odor, color, disease causing microorganisms, debris,
sludge, as well as chemicals, by taking samples from each operating machines,
whether they are doing their job or not. And all the results will be compared with the
standards present, which are WHO and ESA.

Bore hole Chlorination Raw water tank Sand filter

Reverse Oosmosis Micro filter Softener


Active carbon tank

Ozone mixing tank Purified water tank UV radiation Filler

Figure 4 Process flow chart of water treatment line

Bore Hole

The bore hole is located inside the company’s compound, cutting the raw material transport
cost to almost zero. The hole is well preserved and has a depth of 183m. There is a pump
alongside the hole, with 15kw power and pulling raw water in a rate of 3 L/sec.

Chlorination
Chlorination is the addition of the already prepared Chlorine solution to the tanks in a
proper doze recommended by the chemists. 800g of chlorine to 500L water, then the
solution is added at the rate of 0.5pm to the tanks by a pump. The purpose of addition
of Chlorine to the raw water is to kill bacteria, virus, and other microbes if present in
the raw water. In particular Chlorination is used to prevent the spread of waterborne
diseases such as cholera, dysentery, and typhoid.

Raw Water Tanker


There are two raw water tanks, having the capacity of storing 25,000 liters of raw water
each, well preserved from sunlight and used for storing raw water.

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Sand Filter
Sand filtration is a type of water filtration equipment which works by providing the
particulate (suspended) solids with many opportunities to be captured on the surface
of a sand grain. Sand filters are used as a step in the water treatment process of water
purification. There are three main types; rapid (gravity) sand filters, upward flow sand
filters and slow sand filters. All three methods are extensively in the industry used
throughout the world. But in mogle bottle water manufacturing company industry
there is a rapid sand filter. Sand filters can, apart from being used in water treatment
plants, be used for water purification in singular households as they use materials
which are available for most people.

Figure 5 Sand filter tanker

Activated carbon filter


Activated carbon, also called activated charcoal, is a form of carbon processed to have
small, low volume pores that increase the surface area available for adsorption or
chemical reactions. Activated is sometimes substituted with active. Carbon filtering is
a method of filtering that uses a bed of activated carbon to remove contaminants and
impurities using chemical adsorption. Each particles/granular of carbon provides a
large surface area/pore structure allowing contaminants the maximum possible
exposure to the active sites within the filter media. See the following figure in detail.

The main purpose of activated carbon filter is to remove the chlorine residue from

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Chlorination process, taste, and odor, by adsorption

Figure 6 Carbon filter and activated carbon

Softener
Softener does the job of removing Calcium and Magnesium, typically and certain
other metallic ions that makes water hard. The mechanism softener works is by ion
exchange. Hardness ions in the water, primarily calcium and magnesium are
exchanged on the ion exchange resin for sodium. When all available exchange sites
are converted from sodium to hardness, the softener is exhausted and needs to be
regenerated. Regeneration is achieved by exposing the ion exchange resin to a brine
solution. The brine concentration is high enough the resin replaces the hardness ions
on the resin with sodium ions. The hardness ions removed from the resin, along with
some excess sodium and chloride ions, are sent to the drain.
Micro Filter
A type of filtration process where a contaminated fluid is passed through a special
pore sized membrane to separate microorganism and suspended particles from process
liquid. And there are two type of micro filter 1micro and 5micro. One micro filter less
than one micro particles in the water and five micro filters less than five micro
particles in the water

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Figure 7 Micro filter

Reverse Osmosis
In this stage we can say water is pure because reverse osmosis removes organic and
inorganic ions. Also removes disinfection which are passed above stages. RO have a
gauge, if RO is not normal gauge decreases also decreases flow of water to pure water
tank. There is CIP tank which is used to clean RO. Reverse osmosis uses an applied
pressure gradient across a semi permeable membrane to overcome osmotic pressure
and remove water molecules from the solution with hardness ions. The membrane has
pores large enough to admit water molecules for passage; hardness ions such as Ca 2+
and Mg 2+ will not fit through the pores. To maintain the PH of the water we use
sodium bi carbonate.

Figure 8 Reverse osmosis membrane

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Pure Water Tank
In this stage the pure water stores which comes from reverse osmosis stage. Then by
intermediate pump moves to ozone mixing tank.

Ozone Generator
It is used to generate Ozone (O3). Ozone is produced when oxygen (O2) molecules are
dissociated by an energy source into oxygen atoms and subsequently collide with an
oxygen molecule to form an unstable gas, ozone (O3), which is used to disinfect water

Ozone Tanker
At this stage the mixing of water and ozone occurs. Then the disinfection of water will take
place

2.3.2. Bottle Water Production Process Steps


Air Compressor
An air compressor is a device that converts power (using an electric motor, diesel or
gasoline engine, etc.) into potential energy stored in pressurized air (i.e., compressed
air). By one of several methods, an air compressor forces more and more air into a
storage tank. The energy contained in the compressed air can be used for a variety of
applications. When tank pressure reaches its lower limit, the air compressor pressure
reaches its engineered upper limit, the air compressor shuts off. The compressed air
turns on again and re-pressurizes the tank. Air compressor room supply air into
production room
Two types of air compressor: -

High Pressure compressor: - Only in Blowing.

Low Pressure compressor: - Used in all production room and treatment room.

Pressure
Air enters compressor filter, the filter filters air and removes dust. Then filtered air
passed to compressor tank and goes to refrigeration air drier. In the air drier water is
removed and hot water cool down. Also, there is two types of pressure used during
the production high pressure and low pressure. The high pressure used for blowing
machine.

Blow Molding

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Blower machine is a machine where a melted perform is inflated with a high pressure
to form a desired bottles shape with a help of molder equipment as stretcher extended
to limited length. As the perform are different for different sizes of bottles, so are the
molds. The following steps are necessary for the preform to pass in order to be a
bottle.
Perform Hopper: It is a place where the purchased preform is fed to a bucket of
metal that will feed the conveyors.
Trim: as preform comes from preform hopper through inclined belt conveyor the trim
arranges the preform to proper order or position.
Feeder: this uses only to feed the arranged preform to blower by reading sensor
alarm. Also, in blower machine there are four sections termed as:
Star: in this machine there are three stars that feed preform to oven chain and use to
exhaust inflated bottle from grip out to air conveyor.
Grip: here there are three grips; grip in, that take the melted preform from oven chain
and provide to molder, and grip out that send the molded bottle to air conveyor
through exhaust star.
Oven: The preform that comes from feeder through star melted in this tool with
300kv electrical charge.
Molder: The melted preform enter into molder through grip in to inflated with high
pressure by extending stretcher into melted preform and cover with a seal to
compressor.

Figure 9 Blowing machine

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Filler Machine
Is a machine which is used to fill (package) the bottles with product.

Has two main processes;

 Filling

 Capping/Crowning

Filling machine
The main machines, devices and materials used in filler machine are listed below:

1. Photo electric cell for gap detection

Is used to ensure that no gaps appear in the bottle flow in front of the stop star wheel.
2. Stop star wheel

Is used to stop and pass (release) the bottles.

3. In feed worm shaft

Used to maintain proper spacing to machines pitch.

4. In feed star wheel

Picks up the bottles from the in-feed worm and transfer it to below the filling valve.
5. Bottle present signal sensor (proxity sensor)

Informs the controller if bottles are present.

6. Centering bell

Centers the bottle below the filling valve.

7. Lift cylinder

Raises the bottle and presses it on to the filling valve.

8. Bottle detection for fillers with an automatic splinter washout system

If a bottle has burst then a sufficient area around the affected filling valve is sprayed
with water.
9. Transfer star wheel

Picks up the bottle from lift cylinder and transfer it to sealing head.

10. Discharge star wheel

Transfer crowned bottles to the discharge conveyor.


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Driving mechanism of filler
For driving all machinery in the filling machine one main motor is used. The motor
drives the main gear using belt and act as a machine brake which is it stops from
driving the machine if there is a malfunction. The roller is lifted upward by cam
mechanism and the lift cylinder downward to release the bottle and transferred to
capping stage by transfer star wheel Filler rising and capping section in which, the
bottle rinsed, filled with water and capped. The machine can fill up to 80 bottles at
once.

Figure 10 Filling machine

Crowning/Capping machine
Crown is transferred from crown box (hopper) by 2 belt conveyors. One conveyor lifts
crown upward using magnetic system. The sorter orders the entrance of the crown and
flip the crowns if they are unturned. Crown puncher has a magnet attached to it to hold
the crown for some seconds and punches the crown on the bottles. The crown puncher
rotates by gear driving mechanism

Figure 11 Capping machine Date coder

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Date coder is a machine which is used to paste (stick) date of production and expiring
date on the bottle without direct contact. It has inductive sensor to sense the crown’s
availability on the bottle. The coder works when the sensor on the conveyor reads the
bottle moving on the conveyor and sends the information to the coder. Then having
the information from sensor and using ink jet, writes best before date (BBF) and
printing time and date (PRT).
Bottle drier
Used to dry the vapor on the bottle and the bottle moves on the motor conveyor passes
through date coder

Inspection Bench
Inspection bench is bench in which the clarity of water checked by vision. There is also
inspection light to check the clarity.

Labeling Machine
Labeling machine is used to label the product with full information of the company
product. Indicate name of the product, company name, chemical analysis information
and logo of the company. It is also a machine which is used to label the label
magazine on the bottle.

In parts of labeler with their importance:

 In feed worm: - Spaces the bottle to the machine pitch.

 In feed star wheel: - Picks up the bottles from the in-feed worm and transfers it to a plate
which are driven by servo motor.
 Glue pump: - Is used to transfer glue from its container on the roller.

 Roller: - Is used to transfer glue to a pallet machine when it is rotating.

 Pallet: - Is a rotating machine driven by gearing system. The glue on the pallet is
transferred to label magazine.
 Gripper: - Is used to take the label from the pallet and pastes (sticks) it on the bottle.
 Brushes: - Are used to brush the label to the bottle when the bottle passes.

 Servomotor: - Is used to control position. Used to reciprocate (rotate at given angles)


bottles on the plate.

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Figure 12 Labeling machine

Packing Machine
Group packing machine groups the bottle in to 6 or 12 based on the manufacturing
bottle. There are sensors which are very useful to operate the machine. The bottles
come on the conveyor enters the machine.
Belt Conveying System
The factory uses belt conveyor to transport the bottled water starting from filling machine up
to packaging machine. According to the arrangement, it comprises of a horizontal conveyor
and curved conveyor. It is a simple structure which is easy to maintain.

Storage and Transportation of the Product


The end product is stored and transported under such conditions. Preclude
contamination with and/or proliferation of micro-organisms and protect against
deterioration of the product or damage to the container. During storage, periodic
inspection of the end product should take place to ensure that only drinking water
which is fit for human consumption is dispatched. Storage is done with pallets
keeping distance from walls and in between. There is free area to move between each
lot for cleaning, inspection etc. Products are stored according to their production date.
mixing different day’s production is not allowed.

2.4. Work Piece or Work Task I Have Been Executing


The company has other production company of raw material for bottle and cup
production from different area. Then the material will arrive to the company with
different trucks. I have been helping the workers when they transport the material

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from outside of the production room to the inside. I also help the operators in their
daily activity tasks. I take manual from each machine and I work the technical
analysis in the plant and workshop room.

2.4.1 Starting Method of Motor


In general, there are many basic methods of starting motors.

 Direct-On-Line (DOL) starting.

 Star-Delta or Wey-Delta starting.

 Forward/Reverse starting.

2.4.2 Direct On-Line (DOL)


The Direct On-Line (DOL) starter is the simplest and the most inexpensive of all
starting methods and is usually used for squirrel cage induction motors. It directly
connects the contacts of the motor to the full supply voltage. The starting current is
very large, normally 6 to 8 times the rated current. The starting torque is likely to be
0.75 to 2 times the full load torque. In order to avoid excessive voltage drops in the
supply line due to high starting currents, the DOL starter is used only for motors with
a rating of less than 5KW.

Working principles of DOL


The DOL starter consists of a coil operated contactor K1M controlled by start and
stop push buttons. On pressing the start push button S1, the contactor coil K1M is
energized from line L1. The three mains’ contacts (1-2), (3-4), and (5-6) in fig are
closed. The motor is thus connected to the supply. When the stop push-button S2 is
pressed, the supply through the contactor K1M is disconnected. Since the K1M is
deenergized, the main contacts (1-2), (3-4), and (5-6) are opened. The supply to motor
is disconnected and the motor stops.

Advantage of DOL starter


 Most economical and cheapest starter.

 Simple to establish, operate and maintain.

 Simple control circuitry.

 Easy to understand and trouble shoot.

 It provides 100% torque at time of starting.


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 Only one set of cable is required from starter to motor.

Disadvantage of DOL starter


 It does not require the starting current of the motor.

 high starting current.

 mechanically harsh.

 Voltage Dip: there is a big voltage dip in the electrical installation.

 High starting torque: unnecessary high starting torque even when not required by the
load.

Figure 13 Power and control circuit of direct online

2.4.3 Star Delta Starter Method


The star delta starting is a very common type of starter and extensively used,
compared to the other types of the starters. This method used reduced supply voltage
in starting. The following figure shows the connection of power and control circuit of
star-delta starter. The method achieved low starting current by first connecting the
stator winding in star configuration, and then after the motor reaches a certain speed,
throw switch changes the winding arrangements from star to delta configuration. By
connecting the stator winding, first in star and then in delta, the line current drawn by
the motor at starting is reduced to one-third as compared to starting current with the

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winding connected in delta. At the time of starting when the stator winding are start
connected, each stator phase gets voltage VL per √3 where VL is the line voltage.
Since the torque developed by an induction motor is proportional to the square of the
applied voltage, star- delta starting reduced the starting torque to one-third that
obtainable by direct delta starting.

Advantage of star delta motor starter


 Star delta starter is probably the most common reduced voltage starters. It is used an
attempt to reduce the start current applied to the motor during start as a in means of
reducing the disturbances and interference on the electrical supply.
 It reduces the mechanical stress on the motors hence less motor burning is caused.
 The operation of the star-delta method is simple and rugged.
 The star delta starter is manufactured from three contactors, a timer, and a thermal
overload. The contactors are smaller than the single contactor used in a direct online
starter as they are controlling winding currents only. The currents through the
winding are 58% of the current in the line.
 The starting torque is reduced to about 33% of the torque available at a direct online
start.

Disadvantages of star delta starter


 The motor must be delta connected during a normal run, in order to be able to use this
starting method.
 It has a long starting time compared to the DOL starter.

 The soft stop function is not possible like soft starters. The motor stops directly.

Figure 14 Power and control circuit of star delta starting method of motor

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2.4.4 Forward/Reverse Starter Method
To change the direction a three-phase induction machine rotates two of its phases
needs to be changed, thus changing the phase sequence from (say) ABC to CBA. This
can be accomplished by making use of two contactors, one for the Forward and one
for Reverse. Forward reverse operation of motor is required for lift to move up and
down and for mixer.
Advantage forward/reverse motor starting

 Forward Reverse starters are widely used due to their relatively low price.

 There are no limits to the number of times they can be operated.

 The starting current is reduced to approximately one-third.

Figure 15 Power and control circuit of forward/reverse starting method of motor

2.5 Methods and Procedures


To fulfill my internship work, I have used the following methods and procedures.

2.5.1 Methods

I used the following method to carry out my issues.

 Observation

 By asking the machine operators and supervisor

 Using internet and company manual to know individual equipment or materials.

 By doing some works which i observed before and etc.

2.5.2 Procedures
 To start the work, I check myself whether I fulfilled safety rule or not.

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 Then we checked weather the plant gets three phase powers or not.

 And also, we checked each motor on individual machines are switch on to run the
system or to begin work.
 Check in whether or not every machine should be at proper position.

 Then we work what we are going to done.

I was studying and observing how the company processes raw groundwater into a
purified, safe and quality water and bottle it and how the bottles became bottles the
first four months. Then I managed to study how each and every procedure operates
and what exactly happens at that process.

2.6 How Good I Have Been in Performing My Work Tasks


I was good enough while performing my work tasks. It is to mean that I read the
manuals; we consult patiently the engineers and operators without prolonging the
maintenance and productive time. I have participated in this internship and I expect
that only practical knowledge will be gained in the internship but after completing of
the internship I was able to realize that I get many benefits.

2.7 Challenges I Have Being Faced

 Lack of pre use of industry material.

 There is no manual and library in the factory.

 Lack of safety wear like safety shoe and clothes.

2.8 Measurement I Have Taken to Overcome These Challenges


To overcome lack of safety by using own clothes, shoes and others. Sometimes by
borrowing from others. To overcome lack of library by communicating and discussing
with experienced operator who know the machines working principles. By working
with our technician and staff members to know how the maintenance is done and by
referring different materials. To overcome the team works with another department.
In a factory the technical problem is solved by team work i.e., mechanical department
work with electrical department. This is to understand many mechanical parts that are
found in the factory. When they work together with the mechanical department, they
show us different mechanical parts, and vice versa for them too. Also, i used internet
and different website related to my internship work.

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CHAPTER THREE
3 OVERALL BENEFITS GAINED FROM INTERNSHIP
This internship practice has been a great help in understanding and converting my
theoretical knowledge into practical application. It also plays a significant role in
improving my concept real life of a professional by exposing me to the real world and
the challenges that come with it. This has helped me in finding ways to overcome
these challenges that come my way challenges also include financial management,
time management and many more. Internship practice relates theoretical knowledge
and practical knowledge to enable the trainer to interpret knowledge with real world
life. This internship also had a big impact on our qualities as future professionals like:
-
 Improving practical skills.

 Upgrading theoretical knowledge.

 Interpersonal communication skills.

 Understanding work ethics and related issues.

 Improving leadership skills.

 Being able to be a team player.

 Develop entrepreneurship skills.

3.1. In Terms of Improving Practical Skill

This internship practice has been of a great help in terms of improving practical skills
at a large-scale industry. These practical skills come from integrating my theoretical
knowledge with practical skills gained from operators of different of the heavy
machinery. Some of the practical skills I gained during this internship practice time
are: -
 Different approach towards solving problems during production.

 Critical thinking and the ability to evaluate design plans and projects.

 Clear written and oral communication skills.

 Operating skill on the machinery in the company.

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Sampling, and execution of different laboratory tests for quality analysis.

 Understanding of ethical issues and its overall impact on the work environment.
Having a relationship based on mutual respect and kindness between me and
coworkers has helped in achieving these practical skills.

3.2. In Terms of Upgrading Theoretical Knowledge


This internship program has given to me the chance to increase my theoretical
knowledge by introducing me to new machinery and technologies that i weren’t
aware of. The introduction of new technologies has challenged for me to increase my
theoretical knowledge towards that new technology since theoretical knowledge is the
base for increased practical skill towards the technology or machine. And this
theoretical knowledge has helped me to understand the practical observation i see at
the factory by co relating it with my knowledge from my academic studies.

3.3. In Terms of Improving Interpersonal Communication Skill


Interpersonal communication is the process by which people exchange information,
feelings and meaning through verbal and nonverbal messages. In this internship
practice my interpersonal communication skill of enormous help in getting us the
necessary practical skill and information required during this internship practice
period. Not being able to communicate clearly with coworkers at a work place makes
it extremely hard to be competent worker. It might even result in demotion and losing
a job. During this internship practice i have come to understand that communication
skill is not something that should be overlooked as many people do. Interpersonal
communication skill has developed during i stay at the Mogle bottled water
manufacturing company due to day-to-day communication with different workers at
different level of work including supervisors, lab technicians and operators. Increased
communication skill can be achieved by having a confidence, and willingness to say
the wrong thing at times. Some of the additional experiences i have learned to
improve are the following; -
 To understand and communicate with certain workers on level that is suitable for
them.

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 To effectively communicate with workers of different backgrounds in different
sections of the company.

To be able to communicate with operators.

 To communicate with all workers of different shifts to figure out some of the
problems in the production process.
 The improved communication skills have helped me in boosting my confidence.

3.4. In Terms of Improving Team Work Skill


Team work skills are the qualities and abilities that allow us to work well with others
during conversions, projects, meetings or other collaborations. Having team work
skills is dependent on ability to communicate well, actively listen and be responsible
and honest. Therefore, team work skill is a very crucial skill in order to have a
harmonious work environment. To be a good team player being understanding,
accountable, committed and flexible towards fellow coworkers. Having a good team
work skill is not only advantageous, the company but also the team player by
maximizing the individual’s strength by bringing out their best. This can be achieved
by respecting and listening to each other’s ideas that arise. My team playing skill has
increased during i stay at the Mogle bottled water manufacturing company because of
the lifted team spirit that exists between the fellow coworkers, which has played a big
role in the success of the brand.

3.5. In Terms Of Improving Leadership Skills


Leadership is the art of motivating a group of people to act towards achieving a
common goal. In a business setting, this can mean directing workers and colleagues
with a strategy to meet the company’s needs. This leadership definition captures the
essentials of being able to inspire others and being prepared to do so. Leadership is
the art of motivating a group of people to act toward achieving a common objective.
A leader inspires others to act while simultaneously directing the way that they act.
They must be personable enough for others to follow their orders, and they must have
the critical thinking skills to know the best way to use the resources at an
Organization’s disposal. A good leader has five essential skills and those are:

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Communication.

 Motivation.

 Positivity.

 Creativity.

Feedback.

During my internship practice stay in Mogle bottled water manufacturing company


production I have come across many leaders from different section and positions in
the company, and during that time i have seen some exceptional leadership skills from
different employees at the company.

3.6. Understanding Work Ethics


A work ethics is a set of moral principles a person uses in their job. People who
possess a strong work ethic embody certain principles that guide their work behavior
to develop and process a strong work ethic will inevitably result in the production of
high-quality work which is consistent. The output motivates them to stay on track.
The characteristics of work ethics are attitude, behavior, respect, communication and
interaction with others. Any company in any part of the world requires a good ethical
behavior from its employees as much as their professional skill. Development of
ethical conduct within any company is helpful in having a healthy, sustainable and
increased productivity. Some of the work ethics in Mogle bottled water
manufacturing i had to follow were:
Reliability.
 Honesty.

 Cooperating with coworkers.

 Punctuality.

 Taking responsibility for my actions.

 Proper dressing.

 Effective time Management.

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 Initiative.

 Self-discipline.

With respect to work ethics related issues i have seen how workers struggles for
fulfilling their responsibility at work place, respecting their working time and the
order given by the company manager, etc.

3.7. In Terms of Entrepreneurship Skills


Entrepreneurship is the act of creating a business or businesses while building and
scaling it to generate a profit. But as a basic entrepreneurship definition, that one is a
bit limiting. Entrepreneurship is the ability and readiness to develop, organize and run

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business enterprise, along with any of its uncertainties in order to make a profit. The
most prominent example of entrepreneurship is the starting of new businesses. The
entrepreneur is defined as someone who has the ability and desire to establish,
administer and succeed in a startup venture along with risk entitled to it, to make
profits. A few characteristics of entrepreneurs are: -

Ability to take a risk- Starting new venture involves a considerable amount of failure
risk. Therefore, an entrepreneur needs to be courageous and able to evaluate and take
risks.

Innovation- It should be highly innovative to generate new ideas, start a company and
earn profits out of it.
Visionary and Leadership quality- To be successful, the entrepreneur should have a
clear vision of his new venture.
Open-Minded- In a business, every circumstance can be an opportunity and used for
the benefit of a company.
Flexibility- An entrepreneur should be flexible and open to change according to the
situation.
Know your Product- A company owner should know the product offerings and also
be aware of the latest trend in the market. Being able to be accountable and then alter
as needed is a vital part of entrepreneurship.
The basic entrepreneurship skills that I have learned during I stay at Mogle bottled
water manufacturing company are:
Business planning.
 Financial literacy.

 Team building.

 Risk assessment.

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CHAPTER FOUR

4. PROBLEMS IDENTIFIED AND SOLUTION PROPOSED


4.1. Problems observed

• The Machines of the company comes from different Countries they did not
match or compatible each other in good way.
• Improper application of sensors.

• Turn on discharge conveyor due to improper running of Motors.

4.2. Proposed Solution


• Cleaning the sensors from dusts and other things as well as check the
performance during its operation not only during the occurrence of the
problem.
• The motor that is used to rotate the conveyor should be controlled in its speed
by the sensor.

PROJECT SELECTED

4.3. Water Tank Level Controller by using PLC

Abstract
Automation has been an integral part of industries which provides safety, accuracy,
efficiency and less human intervention with dangerous chemical process. So, our
project work is on “Water Tank Level Controller by using PLC”. Water level
management using PLC is design to control the level of water and avoid wastage of
water in the tank. The system has an automatic pumping system attach to it. We are
controlling the water level by using PLC, Sensors and motor.

The purpose for doing this project is reducing time consumption and human resource
consumption, increase product revenue and greater accessibility or more security. Also
by using this project the wastage of water occurred by overflowing of tanks can be
avoided. In future by making some changes this project can be used in different

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industries related to fluids like petroleum industries or oil refineries for controlling the
level of filling the tanks and avoid wastage.

4.3.1. Introduction
A Programmable Logic Controller, PLC may be a computer used for automation of
mechanical device processes. It is used for automation of industrial purposes by using
“Ladder Logic”., the PLC is designed for multiple inputs and output arrangements.

In our project we are using logo soft comfort V.8 software PLC. The project “Water
Tank Level Controller by using PLC” is designed to monitor and control the level of
liquid in the tank.

The proposed system will control the liquid level of the tank continuously and will
ensure that a sufficient level of water is maintained in tanks. This system can be used
in industrial application. It can be used to prevent industrial accident by overfilling of
any open container and to prevent overfilling of any closed container thereby creating
overpressure condition. The system is operated by PLC so there is no need of human
interference this could save the human resources and provides protections to
individuals from danger of industrial accidents. The system is highly reliable,
4.3.2. Problem Statement of the projects

Sustainability of available water resources in many reasons of the world is now


dominant issue. This problem is quietly related to poor water allocation, wastage of
water is the most common problem in different company. So, water monitoring and
controlling are the best possible for reducing the wastage of water in different
company.

4.4 Objective of the project

4.4.1 General objective

Water tank level controller by using PLC

4.4.2. Specific Objectives.


To control level of tank water by using level sensor

To indicate low level tank by using low level sensor

To indicate high level tank by using high level sensor

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To turn of the motor based on sensor

4.5 Significance of the project

Any project aim is to solve a problem and find the way to simplifies people’s life.
Similarly, the Water Tank level control will improve the effectiveness of the
dispatching of Water and it will also help both the company and the costumers. Not
only that, we have also got experience and knowledge about PLC and using them in
many applications while doing this project. Surely speaking this project gives us hope
and confidence in our field of specialization.

4.6 Scope of the project

This project is to design PLC that can be used to control water level tank by adjusting
the level and the rate of it. Our scope encompasses

• To be familiar with PLC (programmable logic controller) and ladder diagram


programming for an industrial application.
• Performing simulation by using logo soft comfort V.8 software.

4.7 PLC (Programmable Logic Control)


PLC stands for “Programmable Logic Controller”. A PLC is a computer specially
designed to operate reliably under harsh industrial environments – such as extreme
temperatures, wet, dry, and/or dusty conditions. PLCs are used to automate industrial
processes such as a manufacturing plant’s assembly line, they both have a power
supply, a CPU (Central Processing Unit), inputs and outputs (I/O), memory, and
operating software (although it’s a different operating software).

Application of PLC
• the is used in civil applications such as washing machine, elevators working
and traffic signals control.

• It is used in travel industry for escalator operation, monitored safety control


system It is used to reducing the human control allocation of human sequence
given to the technical equipment’s that is called Automation

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4.8. Methodology
Block diagram represents the idea of processes that takes place when input is given by
using ladder logic to the PLC. Level sensors are used as input to the PLC and
according to that reading the PLC will give output by using pump and solenoid valves

Figure 16 Block diagram

FLOWCHART

Figure 17 Flowchart

When we switch ON the power supply, pump will start pumping the water in tank 2
through tank

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1 and control valve (CV). When upper threshold of tank 2 is achieved then sensor 2
will sense the water level of tank 2. S2 will send the signal to the PLC about upper
threshold of tank 2. Now, PLC will send the analog signal to the control valve (CV) to
interrupt the liquid flow. Then water will fill the tank 1.

When upper threshold of tank 1 is achieved then sensor 1 will sense the water level of
tank 1. S1 will send the signal to the PLC about upper threshold of tank 1.PLC will
send the analog signal to the pump. Pump will stop pumping water to tank. When
water from tank 2 is drained out sensor 2 will sense the lower threshold of water level
in tank 2. S 2 will send the signal to the PLC about lower threshold of tank 2.PLC will
send the analog signal to the control valve (CV) to let the liquid from tank 1 flow in
tank 2. When lower threshold of tank 1 is achieved then sensor 1 will sense the water
level of tank 1.S1 will send the signal to the PLC about lower threshold of tank 1. PLC
will send the analog signal to the pump. Pump will start pumping water to tank This
operation will take place continuously and required result is obtained.

Figure 18 flowchart of water level control

4.9. Material Requirements of the Project

Level sensor: A low-energy float within these sensors measures liquid level at a
certain point.

Water pump motor Water pump is used to feed water to the reservoir tank shell it is
one of the most important components, it starts automatically whenever there is water
at the threshold level and this will keep the reservoir water level always above the
threshold level. The water pump provides constant flow of feed water to the reservoir
tank.

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Programmable Logic Control (PLC): Programmable logic controllers (PLCs) are
members of the computer family capable of storing instructions to control functions
such as sequencing, timing, and counting, which control machine or a process

CPU: The CPU, which is the brain of a PLC, does the following operations.

 Updating inputs and outputs and Performing logic and arithmetic operations

Memory; Memory is the component that stores information, programs, and data in a
PLC.

Input modules and output modules: A PLC is a control device. It takes information
from inputs and makes decisions to energize or de-energize outputs. The decisions are
made based on the status of inputs and outputs and the ladder logic program that is
being executed

Power Supply
PLCs are powered by standard commercial AC power lines. However, many PLC
components, such as the CPU and memory, The PLC power supply converts AC
power into DC power to support those components of the PLC.

Ladder logic: Ladder diagram is kind of graphical programming language that


changed the relay control wiring circuit diagram.

Switches: Switches are the basic components of PLC. Two types of switches are
available in

PLC. Digital switch (ON/OFF) and Analog switches (continuous varying

Relays: In General, Relays Transform a Control Signal into a Control Action.

4.10. Result and Discussion of PLC Simulation

level Control: the level is checked by the level sensor and if it is above or below the
settled position.

In appendix A, figure shows the ladder diagram of reservoir tank level control. The
operation sequence of the diagram described as follows:
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When low level sensor operates energizer coil (Q1) energized through make contact
and break contact, then after 10 second delay the pump motor (Q2) is ON and boiler
heater (Q5) is activated. The pump motor and the heater are internally connected to
energizer coil. When high level sensor operate energizer coil (Q1) is energized
through break contactor, then the pump motor (Q4) is OFF and while pump motor is
OFF still the heater is working.

Level of reservoirs drum control ladder diagram

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Figure 19 Reservoirs drum level control ladder diagram

Level of boiler drum control ladder diagram description

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Table 1 Level of boiler drum control LAD symbol description

Symbol Assigned name Use


I1 Low level Used sense whether the water in the Tank level at low, make on the pump
sensor motor

I2 High level Used to sense whether the water is filled the reservoir tank
sensor
Q1 Energizer coil Used to energizer the feed water pump motor

T1 Delay on timer Give a delay before the motor start


Q2 Pump motor on Indicate motor is start and working
Q3 Tanker full Indicate some signal when the reservoir tank is full
indicator
Q4 Pump motor Indicate the motor is stopped

off
Q5 Heater on Indicate the electrical resistance is working or not

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CHAPTER FIVE
5. CONCLUSION AND RECOMMENDATIONS
5.1. CONCLUSION
Above all the internship program is the crucial or mandatory option to make the
compatible technology students experience in terms of improving real practical skills,
critical thinking, problem identification, problem solving, enhancing inter personal
communication abilities, leadership system, understanding professional ethics. I
observed the principal operation of different machines in the company. Such as
treatment room machine, chiller machine, filler machine, labeler machine, packer
machine, and molder machine. I got practical work experiences and benefits at the
moggle bottle water manufacturing company some of the benefits the internship
offered. to us include;
 Allow me to both make and develop professional contacts, for my future job
search.
 Assist me in developing greater understanding of my strength and weakness.

 The company`s work flow.

 Upgrade my theoretical knowledge.

 Improves my leadership skill.

 Knowing working standards.

 Work ethics.

 Team playing skills.

5.2. RECOMMENDATION
 Lack of safety. The Company was unable to give safety clothes (uniform), safety
shoes, gloves and etc.
 Lack of library. The factory has no library and adequate reference material that
describes how the machine assembles, operating principles and how maintenance
is programmed.

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 There is no funny or Air condition control systems, so to control the condition of
temperature in the company installing the funny system in different position
specially in production room.
 Producing Jar products is one as there is no competition in the market.

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REFERENSES
[1]. www.onewater.com

[2]. Shubha Sharma “Empty and filled bottle inspection system “International Journal
of Emerging Technology and Advanced Engineering, 2018. p. 1122-1238.
[3]. Kalispel T. “PLC based automatic bottle filling and capping system with user
defined volume selection”. International Journal of Emerging Technology and
Advanced Engineering, 2016. 2(8): p. 134-137.
[4]. Muhammad Sidiki and S.A. Che Ghani “Volume measuring system using
microcontroller for automatic liquid filling machine” 2018.
[5]. Bahamas, Y.A. The working principle of an Arduino. in Electronics, Computer
and Computation (ICECCO), 2014 11th International Conference on. 2014.
IEEE.

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