UNIVERSITY OF GONDAR

INSTITUTE OF TECHNOLOGY
DEPARTMENT OF ELECTRICAL & COMPUTER
ENGINEERING
CONTROL STREAM
FINAL INTERNSHIP REPORT
Hosting Company: Gondar Malt Factory
Duration time: Oct 15 -Jan 30, 2012 E.C
By
Getahun Mihret (4508/08)
Abubeker Mohammed (4111/08)
Ayalew Adane (4203/08)
Dawit Fetene (4340/08)
Dawit Kassaye (4341/08)
Eyayaw Getie
Advisor: Mr. Agmuasie
Submission date

GONDAR, ETHIOPIA
Declaration
We have declared that the work is being presented in the report on internship at Gondar malt
factory for the completion of internship program, carried out from Oct 15-Jan 30, 2011 E.C under
the supervision of Mr. Agmuasie All writing things are done based on the internship experience.
Student Name Signature
Getahun Mihret
Abubeker Mohammed
Ayalew Adane
Dawit Fetene
Dawit Kassaye
Eyayaw Getie

This is to certify that the above statement made by the candidate is correct to the best of our
knowledge and belief. This report has been submitted for presentation with our approval.
Name of Advisor Signature
Mr. Agmuasie
Name of Examiner1
Name of Examiner2
This project has been submitted for examination with my approval as a university advisor.

Advisor’s Name Signature Date

Acknowledgement
First of all, we would like to express our hearty gratefulness to almighty GOD for his great
kindness to us. We want to give special thanks to Mr. Agmuasie, our advisor. We also express our
heart full gratitude and indebtedness to Mr. Estifanos, head of Electrical and computer engineering
department for providing this internship program. We also give thankful to Mr. Yehenew, Mr.
Tewodros, Mr. Belete and Mr. Begosew for their scholastic guidance, valuable instructions,
constructive criticism, and constant help in carrying out this internship from the very successful
completion. We also give thankful to Mr. Berihun, Forman in Gondar malt factory. Gondar malt
factory without their effort it would be impossible to bring this report to be light.

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Executive summary
Our internship report starts by describing the overall back ground history of the company, its main
products and services, main customers, vision, mission and value of the company. And also the
production process of malt and mainly deal about the overall internship experience in malt
processing production section and electrical power system components operation. The task that
we have been performing, challenge we have been faced and measure taken to solve problems has
also stated. We also try to identify a problem in in the company and formulate a specific area of
automatically water level controller system and its working principle. Also we try to see the benefit
that we gain from the internship program in regarding to the upgrading theoretical knowledge,
improving practical skill, team playing skill, leadership skill, developing entrepreneurship, the
communication skills and understanding about work ethics has been mentioned. Finally we
recommend the company.

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Table of Contents
Acknowledgement ......................................................................................................................................... i
Executive summary ....................................................................................................................................... ii
List of Figures ............................................................................................................................................... vi
List of Abbreviations ................................................................................................................................... vii
CHAPTER ONE ............................................................................................................................................... 1
1. BACKGROUND OF THE HOSTING COMPANY ............................................................................................ 1
1.1 Brief history of Gondar malt factory .................................................................................................. 1
1.2 Main Product and Services ................................................................................................................. 1
1.3 Its Main Customers ............................................................................................................................. 2
1.4 Vision of the factory ............................................................................................................................ 2
1.5 Mission of the factory ......................................................................................................................... 2
1.6 Value of the factory ............................................................................................................................ 3
1.7 Objective of Gondar malt factory ....................................................................................................... 3
1.8 Structures of organization flow .......................................................................................................... 3
1.9 Over all work flow ............................................................................................................................... 5
1.10 Process description ........................................................................................................................... 6
CHAPTER TWO ............................................................................................................................................. 8
2. OVER ALL INTERNSHIP EXPERIENCE WORK SECTIONS .............................................................................. 8
2.1 Malt processing production section ................................................................................................... 8
2.1.1 Steeping........................................................................................................................................ 8
2.1.2 Germination ................................................................................................................................. 9
2.1.3 Kilning......................................................................................................................................... 10
2.1.4 Deculming .................................................................................................................................. 11
2.1.5 Water treatment .......................................................................................................................... 11
2.1.6 Cooling plant .............................................................................................................................. 12
2.1.7 Boiler plant................................................................................................................................. 12
2.2 Electrical part(section) ...................................................................................................................... 12
2.2.1 Programmable logic controller .................................................................................................. 12
2.2.2 Drive machines........................................................................................................................... 14
2.2.6 Generator ................................................................................................................................... 20
2.2.7 Distribution panel ...................................................................................................................... 26
2.2.8 Bus bars...................................................................................................................................... 27

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 2.3 The work task we have been executing ............................................................................................ 28
2.4 Procedure we have been using ......................................................................................................... 29
2.5 Chalenges we had been faced .......................................................................................................... 29
2.6 Measure taken to solve problems .................................................................................................... 29
CHAPTER THREE .......................................................................................................................................... 30
3. AUTOMATIC WATER LEVEL CONTROLLOR SYSTEM FOR GONDAR MALT FACTORY ............................... 30
3.1 Short summery of the project ........................................................................................................... 30
3.2 Introduction and background ........................................................................................................... 30
3.3 Problem statement and justification ................................................... Error! Bookmark not defined.
3.4 Objective of the project .................................................................................................................... 31
3.4.1 General objective ....................................................................................................................... 31
3.4.2 Specific objective ....................................................................................................................... 32
3.5 Methodology..................................................................................................................................... 32
3.6 Literature review............................................................................................................................... 33
3.7 Theory about automatic water controller ........................................................................................ 35
3.8 Parameteres of design an automatically water tank level controller............................................... 35
3.8.1 Relay and switch ........................................................................................................................ 35
3.8.2 Pump motor ................................................................................................................................ 35
3.8.3 Floating sensors ......................................................................................................................... 36
3.8.4 Designing ....................................................................................... Error! Bookmark not defined.
3.9 Results ............................................................................................................................................... 36
3.10 Discussion and conclusion .............................................................................................................. 37
CHAPTER FOUR ........................................................................................................................................... 37
4. OVERALL BENEFITS WE GAINED FROM INTERNSHIP .............................................................................. 37
4.1 Improving or upgrading theoretical knowledge ............................................................................... 38
4.2 Improving practical skill .................................................................................................................... 38
4.3 Improving industrial problem solving capability............................................................................... 39
4.3.1 Problem identification ................................................................................................................ 39
4.3.2. Solution to problems ................................................................................................................. 39
4.4. Improving team playing skill ............................................................................................................ 39
4.5. Improving leadership skill ................................................................................................................ 40
4.6. Understanding about work ethics and related issues. .................................................................... 40
4.7 Improving entrepreneurship skills .................................................................................................... 41

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CHAPTER FIVE ............................................................................................................................................. 42
5. CONCLUSION AND RECOMMENDATION ................................................................................................ 42
5.1 Conclusion ......................................................................................................................................... 42
5.2 Recommendation.............................................................................................................................. 43

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List of Figures
Figure 1 Company organization and work flow ............................................................................. 4
Figure 2 Overall work flow............................................................................................................. 5
Figure 3 Process description of malt production ............................................................................ 7
Figure 4 Steeping diagram .............................................................................................................. 9
Figure 5 Germination process ....................................................................................................... 10
Figure 6 Kilning plant ................................................................................................................... 11
Figure 7 Operation of plc .............................................................................................................. 13
Figure 8 Direct on-line starter ....................................................................................................... 16
Figure 9 Star-delta starter.............................................................................................................. 17
Figure 10 Bus coupler ................................................................................................................... 20
Figure 11 Bus bar .......................................................................................................................... 27
Figure 12 Power flow diagram for each plant .............................................................................. 28
Figure 13 Methdology....................................................................Error! Bookmark not defined.
Figure 14 Floating sensor...............................................................Error! Bookmark not defined.
Figure 15 Block diagram of automatic motor tank level control systemError! Bookmark not
defined.

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List of Abbreviations
AWPC Automatic water pump controller
CPU Central processing unit
DC Direct current
DOL Direct on line
Eeco Ethiopian Electric Power Corporation
EMF Electro motive
GCB Ground Circuit Breaker
I current
KV Kilo volt
KVA Kilo volt Ampere
KW Kilo watt
MCB Main circuit breaker
P power
PLC Programmable Logic Control
QC quantity Capacity
R Resistance
RTD Resistance Temperature Detector
SPST Single Pole Single Throw

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 CHAPTER ONE
1. BACKGROUND OF THE HOSTING COMPANY
1.1 Brief history of Gondar malt factory
Gondar malt factory was established on the main road of Addis Ababa to Gondar near Dashen
brewery factory on 4 hectares of land and owned by Tiret is Inaugurated at the presence of his
Excellency Ato Demeke Makonnen Deputy prime minister of FDRE on May 25,2014. The
factory was established with the aim of producing and providing malt for the existing breweries
in the Country. The Factory was established in the region of potential malt barley producing
zones namely: Arsi, western Arsi Bale zones, Northern Gondar from Debark, Southern Gondar
from Raya Giyant, Western Gojjam from Hawi zones and East Gojjam are barley feeder areas
for this company. The Gondar malt factory a capacity to produce malt 16200 tons of malt a year.
It contains 5 barley silos with capacity to hold 26000 quintals each and 4 malt silos with capacity
to hold 18000 quintals each. There are two barley grade silos and one offal silo with capacity to
hold 1800 quintal. conveyers and elevators also raised the hourly carrying capacity from 500-600
quintals. now malt factory is entering an under developed industry increased international and
local investment in Ethiopians breweries and increased the capacity of the five beer factories
currently under operation. The Gondar malt factory hired/building constructor is Afro-Tsion
construction PLC for 97 million birr to handle the civil works in July 2011.Plant procurement,
Installation and electro-mechanical work on the other hand, where machine supplier and erector
is Buhler the German company for a total of 93.7 million dollars in June 2010.It finished the
installation work at cost of approximately 9.75 million dollars.

1.2 Main Product and Services

Delivering quality goods and services can be a major target of any company to stay in
competitive market. In response to the factory has been conducting different types of reform
such as Total Quality Management (TQM), Integrated Performance Measure System (IPMS),
improvement, Business Process Reengineering (BPR) and Management Information System to
improve its system. The implementation of these system enables the factory to improve its
product and quality of product. This factory produces the malt from barley which is the major
raw material for beer production. The raw material, barley has produced to be the most suitable

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malt for beer production. So, the main products of Gondar malt factory is malts that used for
production of brewery and cattle feeds.

1.3 Its Main Customers

Gondar malt factory has supplying barley malt to domestic brewery factory in high quality and
quantity. The factory is trying to profit the country economic development by producing malt
which was imported to the country. So, it saves foreign currency. The main customer of Gondar
malt factory is producing the brewery malt for different factories. among them 12000 tone of malt
will be supplied to Dashen brewery, Harar brewery factory, Bedele brewery factory, Meta brewery
factor and also exports to the outside country. The factory strategic plan by applying the factories
vision, mission and selected strategic targets are organized.

1.4 Vision of the factory

 Producing universally standardized quality malt production and transfer the country’s
foreign market supply.
 To fulfill quality policy of the world.
 To supply inside the country, outside the country & become well known worldwide
company.

1.5 Mission of the factory

 by produce quality malt increase supply of malt in the country and to give support for
investigator (researcher) of barley for achievement of the goal.

 By using modern technology to fulfill quality policy of the world to produce quality malt.

 To become famous malt producer in the world & to save economy of country which is
purchased malt from foreign country & to take responsibility development of the country.

 By reducing countries foreign currency expenditure and contribute for national economic
development and assisting producer of malt barley to increase malt barley production.

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1.7 Objective of Gondar malt factory
The top management of Gondar malt factory is committed to produce and supply quality malt.
The quality policy of Gondar malt factory is thus directed towards the following objectives:
 Ensuring continuous qualitative and quantitative improvement of the malt production.

 Creating awareness to raw barley suppliers to produce and supply the necessary& quality
products.

 Create and maintain a safe and healthy working environment that will foster team.

 To facilitate the entrepreneurs the importance of setting up unit of malt.

1.8 Structures of organization flow

The factory has the functional structure in order to meet its targets that placed in the strategic plan
of the factory. the company produced malt all 24hr per day. Some employee to start work from
one hours up to nine hours (1-9)hours, two hours up to ten hours (2-10)hours, nine hours up to
three hours evening (9am-3pm)hours, from ten hours up to four hours evening (10am-4pm), from
three hours evening up to one hour morning (3pm-1am) and from four hours evening up to two
hours morning Each employee writes report what he/she done.

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 General Manager

Production Administrative & Human power

&technique

Finance office Internal adult

manager

ICT manager Agricultural production manager

Human Finance Marketing Production Quality Production

resource & sales &technique assistance & supply
service

Auto Electrical Mechanical

Production maintenance maintenance
mechanical
section section

Figure 1 .1 company organization and work flow

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1.9 Over all work flow

Raw Ground Barel Barely

Cleaned Pure
barely sale y dust
barley barely
intake intake
line
Offal
3rd 3rd barley
grade grade
(offal) Grading Scaled
(offal)
storage of of pure
barley barley

1st & 2nd grade

barley

Scaled
remaini 1st & 2nd
Choice Steeping Germinatio
ng grade
from 1st or plant n plant
barley Barley 2nd
storage barley

Malt Machine Killing

storage silo Pure plant Cleaned plant
house
malt

Offal

Packed the Transporting

Scaled malt
malt to customers

Figure 1.2 overall work flow

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1.10 Process description
The raw barley delivery to Gondar malt factory compound by the truck .when the truck reaches to
load cell and the truck can be scaled with the barley (the total scale can be takes place).Then the
truck reached to the barley intake line and the barley sample taken from the truck by chemists to
ensure and set the sample to laboratory for full analysis;
 Moisture content analysis

 Protein content

 Germinative capacity.
The checked barley enters into barley intake line. The entered barley can pass through barley intake
line and dust which exist in barley can separated and pass through dust intake line. The barley
entered into the machine house though chain conveyer and the chain conveyer at the 4m under
ground level and there is magnetic separator machine which eliminates impurities and separates
broken particles such as metal, nails, blade, needle, sands, rocks and etc. are eliminated. After
impurities and metallic materials are avoided the barley goes through elevator and reached to 25m
and the barley returned back though bucket elevator and entered into pre-cleaner is drum sieve at
19m. At this stage the heavy metal, rock, and other materials are removed before the barley
entering into pre-cleaner (sieve drum). In the sieve drum the foreign materials and dust can be
eliminated. The pure barley and offal can be separated in this stage. Drum sieve is simple rotating
machine for primary course cleaning to feed storage silo or to the plants for feed to main barley
cleaner it also supplied with aspiration system including fan, piping and cyclone for dust free
operation and better environment.

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 Barley Barley Clean steeping
deliver storage grade

Weigh Polish Germinatio

Kilning
bagging weigh n

Dispatching to customer

Figure 1.3 process description of malt production

Where Qc-quantity capacity

This machine made from steel frame ,drum lined with perforation metal depend up on capacity
requirement and types of seed to be cleaned having spiral blade arrangement for moving material
alongside circumference of drum for better result and also remove all large impurities like stone,
glass ,metal and etc. aspiration system separates loose leaves ,dust for better cleaning performance.
Dust (offal) is collected in dust bin and back to ground level the pure barley is weighing or scale
before transfer to silo at ground level and it entered in screw conveyor pass barley in to another
elevator and goes to 19m before entering to the silo storage by addition of chemical is called
phostoxine. for the sake of malt transfer barley to cleaning and grading process barley clean by
remove foreign matter, dust and the remain barley part will be graded according to barley volume.
grading is action by machine called screening and grading machine. The incoming barley is sorted
according to its width and its thickness respectively. All barleys thinner than the screen holes fall
through the screen, and all thicker barleys remaining in the screening cylinder are transported to
end outlet. The graded barleys; first grade, second grade used for the purpose malt and third grade
(offal) collected in silo and sale as cattle feed. Barley will be stored in grade silo and waiting for
use. Then finally barley transfer to steeping vessel through chain conveyer.

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 CHAPTER TWO
2. OVER ALL INTERNSHIP EXPERIENCE WORK SECTIONS
In the four-month internship program we have been worked at Gondar malt factory. There are two
types of sections that we have done our internship in the factory. These are electrical part and malt
processing production section.

2.1 Malt processing production section

In the four-month internship experience we observe malt factory construction and the basic
elements of malt factory. The factory has main production plants and assistance production plants.
The main production plants are machine tower & silo plant, steeping plant, germination plant,
kilning plant and assistance production plants are pumping station for steeping, germination, and
boiler, boiler for kilning, cooling for germination and steeping, kola diba water supply station and
pumps.

2.1.1 Steeping
During the steeping process, the cleaned barley ready for malting is washed and steeped to rise the
moisture content in the barley so that the enzymes are activated to enhance germination process.
The process is as follows; from silo barley received by small reversible chain conveyor and then
given to steeping elevators, steeping balance, steep chain conveyor and steeping tank. grains that
float and do not germinate due to their size are skimmed in this process. The process usually takes
2-3 days. The required moisture that could facilitate germination is achieved within the period.
water pumps are the main operational devices in which it allows the water and moisture rise up
through the barley.
The steeping plant contain 12% moisture at normal room temperature. At the end of wet steeping
the barley will contain 43-48% of moisture. this achieved by series of wet stand followed by dry
stand. after steeping in water, the first water removed outside from tanks to clean. dry steep is
steeping barley without water is called aeration. It is drive cool air from cooling plant for the sake
of remove carbon dioxide by an aerobic action. If there is carbon dioxide, the acidic media will be
happening and this cause to die the barley. At the end of steeping, the root begins to emerge from

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barley showing as white dot. The hydrated barley exhibits an increase barley respiration and
demand for oxygen which signals the beginning of germination and the steeping barley will
pumping to next process.

Figure 2.1 steeping diagram

2.1.2 Germination
The steeped barley is pumped over to the germination boxes, and then germinates in which the
starch in the barley changes to fermentable sugar. The process takes 3 -6 days of germination
barley is modified by action of specific enzymes on barley structural components depending on
the quality of the barley. small size grains usually germinate faster than large size grains. during
the process, the temperature, airflow and time can be manipulated and the moisture are controlled
to the desired conditions in order to vary the final characteristic of malt. compressed air will supply
to circulation and achieve good mixing and fresh water will be spray to keep moisture. moisture
air supply and perforate plate and recycling to germination room.
There are about 13 induction motors with turner screw, travelling drive machine and wall of
germinating box. largest motor on the machine and which is the one travel the warm turner forward
and reverse in chain or gear system. The screw turner moves fast for the case of turning of the
barley and slow for the case of return. The speed of the motor can be controlled by the frequency
convertor. At the end the green malt will be transferred to kilning house.

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 Figure 2.2 Germination process

2.1.3 Kilning
The green malt is treated with heat 75-100% of degree centigrade and germination process is
completed stopped and humidity decreased down to 3% and the moisture in the green malt is
reduced from (44-46) the kilning taken 1-2 days. enzyme activities terminate and the malt will
have the flavor, taste, and aroma and color in the process. The process is as follows. The green
malt is carried out by green malt loading chain conveyor with valves from germinating box to
kilning house. first, by using loading and unloading machine the malt is poured over the sieve.
then the steam is coming from the boiler with pipes and given to heat exchanger with heating
system and valves and next given to malt by using high power radial fan and the kilning process
takes place green malt will be kiln under control condition by varying temperature in each step.
moisture heat air will be circulated to heat exchanger to recovery heat and then transfer kilned malt
to analysis silo with the capacity to hold 180 quintals.

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 Figure 2.3 kilning plant

production sectioning: in this section we observe malt factory construction and the basic
elements of malt factory. This factory contains main production and sub production plant.

2.1.4 Deculming
The roots and shoots during germination are removed in this process. The removals of the roots
help the malt not to absorb moisture during storage. thus, in the process of deculming, the roots
are polished and then separated from the malt by blowing air into the polished malt by pneumatic
shifter. finally, after going through all the above processes, the malt will be kept in the silos for at
least 2 months before delivery to the breweries, so that the enzymes activated during germination
settles down.

2.1.5 Water treatment

First impure water coming from kola diba outside of the factory through the channel and then, in
the factory aluminum sulfate (500L water for 50kg aluminum sulfate), sodium carbonate (500L
water for 50kg of sodium carbonate) and chlorine (160L water for 50kg of chlorine liquid) is added
to each dosing tank. Then mixed by using mixer after that given to the water by using dosing pump.
Next filtered water is stored to the tanker. There are two water treatment tankers with the capacity
to hold 750-meter cub. within water treatment process there is gauge and meter, clear water pump

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with level sensor and back wash pump with level sensor to control the water purity. Before
transport water to the plant and keep the temperature at 14 degree centigrade. At the end water is
distributed to germinating, steeping and other parts of the factory.

2.1.6 Cooling plant

It is used to germination and steeping for temperature control at these two houses they have needs
cold atmosphere so this plant create atmosphere cold. condenser and heat exchanger. First
ammonia in the form of gas and liquid is added to ammonia tanker with expander and pipe line.
next ammonia is sucked hot gas by compressor and compressed; final ammonia is discharged to
condenser by help of heat exchanger and ammonia separator transported through expansion valve.
Then given to the germinating room and steeping through the pipe and fans. In the house there are
three ammonia compressors with motor of 878KW capacity.

2.1.7 Boiler plant

This house feed hot air for kilning plant According to weather water or combustion gases flow
through the tube’s boilers classified into as:
 fire tube
 water tube
but in Gondar malt factory fire tube boiler is used. water partially fills boiler barrel with a small
volume left above accommodate the steam (steam pace). The heat source is inside a furnace or fire
box that has to be kept permanently surrounded by water in order to maintain the temperature of
heating surface just below boiling point. The source of heat for boiler is combustion of heavy oil
tanker. The furnace come be situated at one end of a fire tube which lengthens of the path of hot
gases that augmenting the heating surface which can be further increased by making the gases
reverse direction through a bundle of multiple tubes. alternatively, the gases may be taken along
the sides and then beneath the boiler through flues. steam production tones/hour. The working
pressure 1.22Mpa, feed water temperature 80-100 degree centigrade and feed water PH 9.5-12.

2.2 Electrical part(section)

2.2.1 Programmable logic controller
It has many "inputs" terminals, through which it interprets "high" and "low" logical states from
sensors and switches. It also has many output terminals, through which its outputs "high" and
"low" signals to power lights, solenoids, contactors, small motors, and other devices lending

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themselves to on/off control. In an effort to make PLCs easy to program, their programming
language was designed to resemble ladder logic diagrams. Thus, an industrial electrician or
electrical engineer accustomed to reading ladder logic schematics would feel comfortable
programming a PLC to perform the same control functions. PLC is a special form of
microprocessor-based controller that uses a programmable memory to Store instructions and to
implement functions such as logic, sequencing, timing, counting, and arithmetic to control
machines and processes and is designed to be operated by engineers with Perhaps a limited
knowledge of computers and computing languages.
Component of PLC
The processor unit or central processing unit (CPU): - This unit interprets the input signals and
carries out the control actions according to the program stored in its memory.

figure 2.4 block diagram of plc

Generally, PLC:
 It is the “brain” of the PLC

 Consists of a microprocessor for implementing the logic, and controlling the

communications among the modules. designed so the desired circuit can be entered in relay
ladder logic form.

I/O Modules: -are the processor receives information from external device and communicates
information to external devices. generally, the function of an input module is to convert incoming
signals into signals that can be processed by the PLC, and to pass those signals to the central
control unit. The reverse task is performed by an output module.

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basic Principle of operation of PLC: -programmable logic controllers’ function by interpreting data
coming through their inputs and depending upon their state, turning on/off their outputs. They are
programmable via software interfaced standard computer interfaces, proprietary languages and
network options.
There are three states of operation of PLC
 Detect incoming signals
 Process it
 Generate outputs to control various devices, it achieves machine control.
2.2.2 Drive machines
In the four-month internship experience we observe the basic elements of malt factory. Gondar
malt factory uses 98% of induction motors; the left 2% uses DC motor and servo motor.
 They are robust or strong and rugged in construction
 Require less maintenance

 Cheaper in cost

 Have high efficiency

 Are widely used for most industrial applications.

1. Induction motors

A three phase induction motors mainly consists of two major parts; the stator and the rotor
separated by a uniform air gap. A three-phase winding suitable wound on the stator is supplied
with thee phase balanced ac supply. A uniformly rotating magnetic field rotating at synchronous
speed is produced. I.e. synchronous speed Ns=120f/p Where p=number of poles, f=frequency. The
line of force of rotating magnetic field cuts rotor conductors and an alternating electromotive force
is induced in the conductors. Then electromotive force generated in the rotor conductors circulates
the current in the rotor winding and the current flowing in rotor winding conductors interacts with
the field produced by the stator winding to produce a torque that responsible for rotation of the
motors. These motors found in machine house used for drive the won fit or separator and in the
kilning plants.

Motor Starting Mechanism: one of the most invention for motor control application is motor
starting mechanism as name indicating that starter is an electrical device which control the

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electrical power for starting motor. This electrical device is also used for the purpose stopping,
reversing and protecting electrical motors. The following are the two major components of starter.

 Contactor: The main function of the contactor is to control the electric current to the
motor. a contactor can make or break power to the circuit. This device is existing main
distribution board
 Overload Relay: Overheating and drawing too much current can cause the motor to burn
out and become practically useless. Overload relays prevent this from happening and
protect the motor from any potential danger. exists in most motors prevent much current
flow.
There are several types of motor starters. However, the two most basic types of these
electrical devices are

Manual Starters: Manual starters are devices that are operated manually. These starters
are extremely easy and straightforward to operate and do not require expert intervention

Magnetic Motor Starters: This is the other main type of motor starter. It is operated
electromagnetically. It means that the motor load connected to the motor starter is typically started
and stopped using a lower and safer voltage than the motor voltage. Just like other motor starters,
the magnetic starter also has an electrical contractor and overload relay to protect the device from
too much current or overheating.

Types of Magnetic Motor Starters

Direct-On-Line Starter: The direct on-line starter is the simplest form of motor starter other
than a manual starter. The controller of this starter is typically a simple push button (but could be
a selector switch, limit switch, float switch, etc.) Pressing the start button closes the contactor (by
energizing the contactor coil) connected to the main supply and motor.

The advantages of using direct-on-line motor starters

 : They have a compact design.

 They are cost-effective.
 They have a simple construction

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 Figure 2 Direct on-line starter

Star Delta Starter: Compared to the other types of starters, the star delta starter is used on
a large scale. As the name suggests, the three windings are connected in a star connection in the
star delta starters. a certain time is set by the timer or any other controller circuit. after this time is
passed, the windings are then connected in the delta connection. The phase voltage in the star
connection is reduced to 58%, and the total current drawn is 58% of normal current. This results
in a reduced torque. These starters exist in the air compressors.

The Advantages of using star delta motor starters:

 They are ideal for long acceleration times.

 They have a lower input surge current when compared to other starters.
 They have a simpler construction as compared to other starters.

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 Figure 3 Star-delta starter

Reverse/ forward motor starting

Forward reverse motor starting has two contactors, the one used for forward the other is used for
reverse rotation. Forward reverse contactors are mechanically interlocked; if one of them is closed
the other cannot close. It is used in a system where forward and backward or upward and downward
movement if the operation is needed. Most of time found in chain and back forward conveyor.
Soft starter: is any device that controls the acceleration of an electric motor by means of
controlling the applied voltage. Soft starter is any device which reduce the torque applied to the
electric motor. Generally, consists of solid-state device like thyristor to control the application of
supply voltage to motor.
Advantage of soft starter
 Improve efficiency
 Controlled start up
 Controlled acceleration of motor smoothly
 Low cost and size

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 Gear box: - mechanical controls of motors. We use gear box to transmit mechanical
energy from a prime mover to an output device and used for changes the speed of motors. This
can be done by using the different size of gears. When the size of gear is increased the running
speed of the motor decreased and when the size of the gear is decreased the running speed of the
motor must be increased. Therefore, the gear box which connected in motor is play important roles
to vary or changes the speed of induction motors and it helps to reduced speed of motors.
Servo Motors: special types of motors which exist in the boiler plant. It keeps the furnace oil
and airs are balanced by ignition transformer to cause spark from butter gas at a time and makes
flame.
If oil is greater than the air it allows closing. The oil valves and if the air is greater than the furnace
oil the servo motor does the same thing with that of oil furnace. Flame sensor balance and adjust
furnace oil and air. It allows the system in proportional and it can be controlled by PLC and
adjustable by the system, if it is adjustable by the manual it may increase whether air or oil furnace
level and it is hard to control the systems.
Turner screw machines: they are 13 in numbers that exists walls of germination used for
move those turner screws to mixes the barley on the vessel on the germination box and remix the
dry part and the wet part of germinated barley.

Travelling drive Machine: this machine consists of gear, frequency, inverter and braking
system. Breaking systems consists of ON and OFF safety switch and it is magnetic material
supplied with 24v, and it is connected with motor shaft. When the break is turned off it blocks the
motor shafts and catch up its alignment. When the power is turned ON it released the motor shaft
and stop immediately. There is also inductive limit sensor it senses metallic materials and keeps
the alignment /straight coupling the shaft and also served as coupling travelling drive machine
with walls.

Limit switch: They are used for control of machine as safety interlock / normally open and
normally closed switch. It is electro-mechanical device that consists of mechanical linked to set of
contacts to make break an electrical connection at normally open position.
Switch gear: -Is the apparatus used for switching or electrical circuits and electrical equipment’s.
It is interrupting currents either under normal or abnormal condition. It also serves as means of

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isolation and circuit protection. Switch gear mainly used for interrupting the current when it
exceeds the normal capacity of the system.
Dc motor: converts electrical power to mechanical power. It is used for only in germination
plant. It works by using comparator, solenoid and copper conductor. There is a set a current value,
when there is an overload the barley pushes the conductor and the current is produced through the
conductor due to this current loss the current value at the solenoid deviates from preset current
value. This digital current value reaches to PLC based on this value gives appropriate response to
the system.
Sensors: Are an electrical input device used to sense different status of a system. It is a device
that receives a stimulus and responds with an electrical signal. It is a device that converts a physical
phenomenon into an electrical signal. The sensor’s output signal may be in the form of voltage,
current, charge, or change in resistance. There are many sensors in production system.

The most common used sensors are: -

Backup switch: -It is an inductive sensor which is used to detect an over load. It is mainly
found at the side of barely conveyor. It works by using comparator, solenoid and copper conductor.
Level sensor: It is a capacitive sensor used to check the status of a container. It operates by
sensing the change capacitance and frequency value. When the dielectric changes, the capacitance
value changes this leads to change in frequency. Level sensor indicates whether the substance is
above or below the sensing point. This is essential to avoid overflow or emptying of tanks and to
protect pumps from dry run.
Temperature sensor: found in kilning and germination plant it is a device used to detect the
temperature of liquid, gas, etc. It commonly used in motor control applications. At kilning plant
detect temperature of house during drying of malt.
Proximity sensors: types of sensors detect position of an object commonly found in with
conveyors and elevators and also gen tuning drive that found in germination plant.
Capacitive sensors and inductive sensor: capacitive sensors detect non-metallic objects whereas
inductive sensors detect metallic objects.
Bus coupler: It is a device which is used to couple one bus to the other without any interruption
in power supply and without creating hazardous arcs. Bus coupler is a breaker used to couple two

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bus Bars in order to perform maintenance on the other circuit breakers associated with that bus
bar. It is achieved with the help of a circuit breaker and isolators.

Figure 4 Bus coupler

2.2.6 Generator
The factory has a supply of 15KV supply from Azezo substation. The emergency generators have
been built to meet the emergency power needs of the malt factory. It starts up if the utility power
is interrupted and the generator automatically switched off. When utility service is returned,
emergency generator has two switches; emergency switch which is used or operate for generator
and normal switch which is operate for main power distribution for the malt plants. The standby
emergency generator is used when the power failure occurred it has capacity up to 1600KV power
supply to the factory. Gondar malt factory has two transformers in the power house. The two
transformers are coupled synchronously in parallel each having 400v.The out let of transformer
connected to the manual transfer switch which is connected to the emergency generator and load.
From main power distribution it is connected like automatic generator to bus bar of distribution
panel. When main power distribution cut-off or normal switch is off, automatic standby generator
immediately become on or emergency switch is on which means normal switch off means
emergency switch on and vice versa. To do a useful work percentage of the electricity being used
is important called power factor. This power factor relay is used as a capacitor bank used to store

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power. For industrial process using electrical motor (to drive pumps, fans, and conveyor)
introducing in efficiencies in to the electricity supply and the other industrial loads are inductive
and operate at low lagging power factor. This inductive nature of load cannot be changed; we can
increase its power factor. The process of increasing the power factor without altering the voltage
or current to original load is known as power factor correction. Induction motor with power applied
and no load on its shaft should draw almost small production power since no output work is being
accomplished until a load is applied. The current with no load associated with this motor reading
is almost entirely reactive power [1]. In calculations we use as it is ratio of active (useful actual)
power to the apparent power expressed in VA. I.e. PF=W/VA
Data’s for generator: -
Speed =1500rpm
Rated Power =1900KVA
Real power =1520KW
Terminal voltage =400v
Weight =13600kg

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Phase =3-phase
Rated current =2746A
Frequency =50 Hz
Cos phi =0.8

Power factor correction

It is defined as the ratio of the real power flowing to the load to the apparent power in the circuit.
It is a dimension less number between 0 and 1. In case of Malt factory the power Factor is 0.8.
Real power is the capacity of the circuit for performing work in a particular time. Apparent power
is the product of the current and voltage of the circuit. The significance of power factor lies in the
fact that utility companies supply customers with volt amperes, but bill them for watts. Power
factor below 1.0 require a utility to generate more than minimum volt amperes necessary to supply
the real power. This increases generation and Transmission costs. Power factor correction units
consist of capacitors which act as reactive current generators. By providing the reactive power,
they reduce the total amount of power you must draw from the network. For the same working
power (kW) they can reduce the reactive Power (KVAR) and the apparent power (KVA) so that
the company will then provide with improved/increased power factor. By this method the power
factor and then the electric power can be stabilized.
2.2.7 Distribution panel
A distribution boards (panels) is an assemblage of parts, including one or more fuses or circuit
breakers, arranged for the distribution of electrical energy to final circuits or to other sub
distribution boards. It consists of a case inside which is a frame holding a number of fuses (circuit
Breaker) carriers. Behind the frame, it is a bus bar to which the incoming sub main is connected.
From the bus bar there is connection provided to one side of each fuse way (circuit breaker). Each
final sub circuit is then connected by the installer to the outgoing terminal of the fuse ways. A
second bus bar is provided to which the incoming neutral and the neutral of the outgoing circuits
are connected. Both single phase and three phases are available. It is not necessary to utilize all
the available fuse ways on board and in fact it is very desirable to leave several spare ways on each
board for future extensions. Bus bars are used to provide power supply to distribution board,
breaking circuits, and fuses. The breaking circuits and substation include providing power supply

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to malting plant, emergency lighting, air conditioning; various socket outlets, and all other control
monitoring equipment.

2.2.8 Bus bars

They are used to provide power supply to distribution board, breaking circuits, and fuses. The
breaking circuits and substation include providing power supply to malting plant, emergency
lighting, air conditioning; various socket outlets, and all other control monitoring equipment.

Figure 5 Bus bar

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In general, the overall power distribution of Gondar malt factory seems as:-

Figure 6 Power flow diagram for each plant

2.3 The work task we have been executing

As we joined in the production and technique department division of the factory, we were perform
different tasks in the company and observed all the department work flow. In addition to improve
our knowledge, we were working with technicians (electricians). In the factory we have been
working with Electricians, operators and other sub division technician’s work in the department;
 Helping electricians and participating while identifying break down.

 Participating on maintenance of breakdown and failure occurred on the machineries and

equipment.

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While working with technicians we understood to apply working principles that workers should
have to follow. Such as holding meter, equipment’s and tools used for specified work that assigned
to perform should have to be applied.

2.4 Procedure we have been using

When we perform all activities in the company, we follow the following procedures.
 First, we wear our safety cloths.
 Follow the instruction of all activities in each work.
 Ask all instruction which is not clear during operation to supervisor.
2.5 Challenges we had been faced
We have faced different challenges while performing our task in the factory. Some are
 It was difficult to get information about problems in the factory.

 We haven’t got access of computer to dig some information necessary for us.

 Some technicians not well trained to deliver full knowledge about the company.

 The chance for the device failure is small; we mostly spent our time by observation of how
the process takes place and how the electric

 Logical control is performed.

 Unwillingness of workers to give a particular task for intern student.

 Unsafe road from university of Gondar to the factory

2.6 Measure taken to solve problems

Some of the above challenges were solved and we give the solution as below; we have told to
production and technique department head to arrange the settle time.
 To gain the knowledge we referred the company manual and reading different materials.

 To have experience we asked the technician of the company repeatedly.

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 CHAPTER THREE
3. PLC BASED AUTOMATIC WATER LEVEL CONTROLLOR
SYSTEM FOR GONDAR MALT FACTORY
3.1 Short summery of the project
The aim of our project is in the company we get manually work water filling and controlling
system so we assume that to modify manually water tank level control system with automatic
means by the help of different components like relay, solenoid valves, motors and water level
sensor are used to control the water level in the water tank with help of PLC. This project switches
ON the motor pump when the water in the tank falls below the lowest level and turn it OFF when
the tank is full. The water level is sensed by two sensors to operate switches for controlling pump
motor.
A Programming Logic Controller is a digital computer used for automation of the
electromechanical process. It is used to convert the previously used relay logic or wired logic for
automation of an industrial process into ladder logic. It is used automate respective process but, in
this project, Siemens LOGO is used which lie in the cheapest category or entry level of PLC. This
paper deals with Automatic Fluid Level Control Using Programmable Logic Controller in Gondar
malt Factory. Currently Almeda Gondar malt factory is used manual control system to control
level of fluid, however there are a lot of limitations, such as wastage, large no of labors, and
difficult to maintained. In order to minimize those problems, we have tried to make Automatic
using PLC. Electronic device used in my project are as sensor - switch, level sensor (limit
switches), As controller: -PLC and pump motor, solenoid valve. Having the above device, I have
also programmed using Ladder logic diagram In LOGO SOFTCOMFORT Software and stimulate
in order to load to PLC

3.2 Introduction and background

In this Paper the Controlling of fluid level tank is crucial mechanism in our day to day activity.
In GONDAR MALT Factory it is common to observe that plentiful fluid is wasted from the tank
and need man power to close and open water silos.
The project “Automatic fluid level control with an automatic pump control system “is designed
to monitor the level of liquid in the tank .The system has an automatic pumping system attached
to it so as to refill the tank once the liquid gets to the lower threshold, while offing the pump
once the liquid gets to the higher threshold. Sustainability of available water resources in many
reasons of the of the world is known dominant issue.
water level in the overhead tank and ensures the continuous flow of water around the clock
without the stress of going to switch the pump on or off thereby saving time, energy, water and
prevent the pump from over working besides this, the liquid level control system are widely used
for monitoring of liquid levels in reservoirs, silos. Proper monitoring is needed to ensure water

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sustainability is actually being reached with displacement linked to sensing and automation, such
a programmatic approach entails PLC based automated water level sensing and controlling.
In order to ensure safety in production and quality of products, effectively and timely control of
liquid level is necessarily in the previous industry people control liquid level through a fixed
liquid level switch .When liquid level is up to certain height, the switch is automatically closed
or disconnected to control water level .But now we are controlling the liquid level automatically
by using PLC, sensor, motor and valves.
Water level control is equipment used to control the water level in a field. The water level is
control using different components like PLC, sensors, motor and valves. The sensors sense the
presence of water and give indication to the PLC .The PLC produce control signal to drive the
motor .If there is no water content the PLC give signal to start the motor and if there is sufficient
water in the field the PLC give signal to stop the motor. It also prevents <<dry run>> of the
pump incase the level in the tank goes below the suction level.
A PLC or programming logic controller is a digital computer used for automation of the
electromechanical process. It is used to convert the previously used relay logic or wired logic for
automation of an industrial process into ladder logic. It is used automate respective process but,
in this project, Siemens LOGO is used which lie in the cheapest category or entry level of PLC.
The reason of it been cheap is that it has limited number of input and output ports. In this project
automation of water tank is achieved by using pressure switch as level sensor in order to set a
low level and high level inside the tank.

Problem statement
The manual fluid level control tank had many disadvantages such as;
 manual fluid level must draw the water manually to the tank when there is no water in the
tank.
 The problem of manual control is sometimes people turn off or turn on the valve.
 For the automatic water level control, if the manual float broken or damages, all the
system cannot function properly.
 There is over flow of in the open container in the industries.
 Time delay
 High cost, less reliable.
 Difficult to maintained

3.4 Objective of the project

3.4.1 General objective
The goal or objectives of this project is designing (theoretically) and simulation-based design an
Automatic water level controller by using plc (programmable logic controller) to maintain the
outlet process of the water level at the desired level.

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3.4.2 Specific objective
 To control and measure the liquid level in the tank
 To designed an Automatic water monitoring system
 To incorporates an interactive medium between the end user and the machine
 To develop controller using PLC as programming.
 To prevent an industrial accident by over filling an open container
 To avoid wastage of Water
 To prevent over labor of the pumping Machine Since the demand of electric city is very
high, Automatic water level control saves energy

3.5 Methodology
There are many methods of designing an automatic fluid level control with switching device but
all this methodology requires human assistance. In this project an Automatic fluid level control for
tank with switching device is designed using electronics control to refill the water without human
intervention the system design was carefully arranged to refill the water tank any time water get
low to a certain level finally the system automatically shut down the water pump by putting the
electric pump off when the tank is full. The tank is to be filled by a pump. The pump will
automatically start when the water level the tank reaches below the low level and inlet valve
becomes open and stop when the level reaches high level.
First, you need to select an instrument or a system that you wish to control. Automated system
can be a machine or a process and can also be called a process control system. Function of a process
control system is constantly watched by input devices (sensors) that give signals to a PLC
controller. In response to this, PLC controller sends a signal to external output devices (operative
instruments) that actually control how system functions in an assigned manner (for simplification

it is recommended that you draw a block diagram of operations’ flow)

Secondly, you need to specify all input and output instruments that will be connected to a PLC
controller. Input devices are various sensors and such. Output devices can be solenoids,
electromagnetic valves and motors.
Third, make a ladder diagram for a program by following the sequence of operations that was
determined in the first step.
Finally, program is entered into the PLC controller memory. When finished with programming,
checkup is done for any existing errors in a program code (using functions for diagnostics) and, if
possible, an entire operation is simulated. Before this system is started, you need to check once
again whether all input and output instruments are connected to correct inputs or outputs. By
bringing supply in, system

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Block diagram off system: The low level and high-pressure switch level sensors serve as DC
inputs to the PLC at input I1, I2, I3and output that is the motor to fetch the water and solenoid
valve to drain the water are connected at out terminals Q1, Q2, Q3 respectively

Low/high
PLC Valve,
level
programmin motor as
sensors as
g out put
input

3.6 Literature review

A good literature review will help you justify researcher’s research and develop your project
position. Buhler Company designed the water tank level that operates and controlled manually.
Believing that water level management approach would help in reducing the power consumption
and as well as water overflow; we are interested to introduce the automatic tank water level
controller system. So, we have reviewed the following researches.
Amrit Kumar Panigrahi, Chandan Kumar Singh, Diwesh Kumar, Nimisha Hota
1. Automation of tank level by using PLC and establish of HMI by SCADA by Rishabh das (2013).
He analyzed the level control of single tank and implemented control strategy. From his paper we
get knowledge about PLC automation that can be used in controlling water level in different tanks.
Also came to know the process of interfacing the PLC to the HMI by using SCADA. Understood
input and output components that are required to connect with PLC
2. “Programmable Logic Controller” article by Kelvin Ericson (associate professor of electrical
engineering at university of Missouri) This article gives guidelines about basic knowledge
of PLC and the ladder logic operations
3. “CosminaIlles” in his research paper “Water level control system using PLC and Wireless
Sensors” in 2013 described water level control system using Siemens 24RL PLC and a pump
controlled by electric motor. They have used wireless sensor for level monitoring.
Assad Ahmed Mohammed Ahmed Automatic water level control system project tittle: based on
Arduino 12, December 2015
Alma D. Salguero Gonzalez and Kyle Russell Marquez Weeks:
There project named „automatic water pump controller‟ monitors the water level of the tank and
keep the pump running. They used water level sensor, microcontroller, pump and relay. The
microcontroller within the AWPC relies on the data from the water level sensors in order to
accurately control the water pump. For simplicity and ease of use, the AC power source provides

Power to the microcontroller, the user-supplied water pump, and relay. The microcontroller then
makes a decision based on the status of the sensors and outputs a flow of water from one tank to

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the other. From the above literature’s we get water level indicator only so we modify the above
generally control system.

Flow chart

start

LLS=1 no

yes HIGH=1 no

yes
Valve off Motor off

Motor=on
Valve on

Motor on

Low no
level=1

yes no

Valve off

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Motor on
3.7 Theory about automatic water level controller
One tank is installed in plant of which liquid level to be controlled. When level reaches the level
low out let flow is blocked and inlet flow is allowed until high level is achieved and when level
high is detected ,outlet flow is allowed and inlet flow is blocked.to detect high and low level of
liquid in the tank ,two level switches are used .which gives out put in digital terms ,that is when
corresponding levels are detected it gives out put high otherwise remains low.
To control level of these single acting piston valve can be used which two states, either fully
open or fully closed. Low level switch is mounted at the bottom of the tank and high-level switch
is mounted at side off upper position of tankers. When these two inputs are detected output to
control valves has to be latched in order to continuously fill or empty the system. Master/stop is
also provided to shut down and start entire process.

3.8 Parameters of design an automatically water tank level controller

This project requires different parameters such as:
 Motor(pump)

 valves

 Push button

 plc

3.8.2 Pump motor

What is a Pump Motors?
Pump motors are used to move or raise fluids.
 Motor is an electrical machine which converts electrical energy in to mechanical energy

 Pump is mechanical device which converts mechanical energy in to into work to be done.
pump is driven by motor only.

 A Pump does not convert one form of energy to a different form of energy, but the motor
converts electrical energy to mechanical energy. The motor only requires an energy source.

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  Pump and motor are two devices that are widely used in many industries. The motor is a
device that is capable of rotating a voltage is applied. The pump is a device that is used to
move fluids.

3.8.3 Push button

Pushbuttons and toggle switches are required in any micro-processor development system for
generating digital input signals.

3. 9 CONCLUSIONS
It has been a great pleasure to work on practice and progress of PLC based fluid level control
system. It provides information about many topics relevant to controlling. system and equipment
automation. We have learned more about water level control system. It can run automatically by
the help of PLC. The great advantage of PLC based water level control system is with maximum
accuracy also the system has higher reliability, small space requirement reduced cost and able to
work as friendly with environment

Simulation and result: When start or I1 is on the pump motor is rotate and the system is start
and inlet valves are open so the tanks start fill if the low-level sensor is indicating.

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If tank is at medium level which means at above low level and below high-level sensors the inlet
valve still open filling system is continue until achieved high level.

3.10 Discussion and recommendation

 It helps in the efficient utilization of available water sources.

 It can provide a major contribution in the conservation of water for the factory.
 It is very beneficial in this industry

 It helps in the efficient utilization of available water sources.

 If used on a large scale, it can provide a major contribution in the conservation of water
for us and the future generations.
This project has achieved the main objectives. Moreover, this project involved designing and
development of automatic water level control system. The system employs the use of advance
sensing technology to detect the water level.
Therefore, automatic water level controller is a simple yet effective way to prevent wastage of
water. Its simplicity in design and low-cost components make it an ideal piece of technology for
the common man.

CHAPTER FOUR

4. OVERALL BENEFITS WE GAINED FROM INTERNSHIP

It is very clear that in addition to the theoretical part, experience is very important in real world.
Being familiar with the work flow is a key to understand one’s role properly and be able to make
competent decisions. For something that takes inputs there is something in return, a benefit. So In
our internship, there were some benefits gained accordingly. The benefits are discussed below.

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4.1 Improving or upgrading theoretical knowledge
Our project has been working at Gondar malt factory. The internship program is not only used to
improve our practical skill but also used to improve our theoretical knowledge, by correlating the
practical skill with theoretical knowledge. But we have not gated enough experience in our
internship program for a specific section. Because no one is interested to see all the proses that
activated at the company, but some points that improved in our theoretical knowledge’s are:
 To know power system and controlling.

 We know electrical machine parts; distribution panel, standby generator, boiler,

compressor, condenser, cooler, fans, pump and etc.

 We have understood the process of plant Understand the control and power distribution
system in the industry.

 To correlate the theoretical knowledge with the real work.

 We got an experience to read and interpret information and ideas presented in electrical
documentation drawings for different types of electrical machines. All the electrical
maintenance and installation system is based on the electrical documentations designed by
engineers.

 We got the benefit in industrial problem-solving capability in the company. To solve the
industrial problem, we must correlate our theoretical knowledge, different instruction
manuals, and asking professional persons.

4.2 Improving practical skill

Internship program is very essential in terms of improving our practical skill, because most of us
were simply familiarize with theoretical knowledge. However, the skills and sound grasp
knowledge’s nurtured by studying electrical engineering practically enables as to solute many
states of affairs like.
 Ability to analyze and interpret diverse complex data.

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  Critical thinking and the ability to understand maintenance, repair, Controller and different
work activities.

 Inter personal communication, persuasiveness and the ability to work as a team.

4.3 Improving industrial problem-solving capability

4.3.1 Problem identification
There are a lot of problem in the company: Among them;
1. Time consuming, Loss of human power, Difficult to move due to heavy weight and dust which
exists in machine house.
2. In machine tower plant there is necessity of lifting system but there is no lifting system in the
machine tower which is the main problem of this plant. The problem is:-
 It is not possible to solve emergency problem immediately

 It is difficult to take heavy motor at the top of the machine tower

 Time loses.
 Road lights are manually working.
3. There is wastage of water because the company is not treating the water.
 4. The security system of the company risks less.
5. Manual water thank control system.

4.3.2. Solution to problems

We have tried to bring the solutions of the factory problems. we have been shared ideas about the
problems of the factory with our supervisor and also comment on other problems.
Solutions taken for the future time are:
 Using lifting system
 Treating water
 Using automatic water plant pump
 Using security protection system (the security system will automatically design in future)
 Road lights are designed automatically with help of different sensors

4.4. Improving team playing skill

Even if, tasks are done by individuals and the respective person at different section of the company
there are times at which different individuals come together to work for common goals of the

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company for increasing productivity. The most important point in team playing skill is just reach
an agreement from different points on the work to be done. For instance, in the case of applying
principle all the factories worker was participating to insure the target of goal. In addition, the
technique division head, Forman’s and technicians discusses on issues that led them to the team
working. Thus, achieving good team playing skill is essential for: -
 Collect (Gain) a good knowledge

 Develop our Communication skill

 Increasing understanding of the task

 Effective completion of tasks

 Saving times and increasing productivity

4.5. Improving leadership skill

Leadership is one of the functions of management which including Planning, organizing, Leading
and controlling. This internship program guides us to be an ethical leader that means ethical
leadership provides the momentum, guidance and motivation among members and effective leader
ship in our working area. In addition to this the intern ship program allow us what a good leader
satisfied or fulfill like a change agent innovative and improve skill for themselves. Therefore, this
is a good correlation between the leader and staff member of the company. Generally, we
understand in four months Internship program is that anyone who is willing to make the effort can
become a good leader.

4.6. Understanding about work ethics and related issues.

Work ethics are generally accepted guidelines for right and wrong behaviors in work place. As
workers made to specialize in different fields specific codes of conduct were expected from each
worker. In today’s complex world, ethical conduct of workers is very important for developing
healthy working environment and increasing productivity. While we were in the factory most
workers told us what misbehavior cause workers to disappear from their working area.
The following principles allow good work ethics in working area are: -
 Punctuality: this means arriving at work on time
 Honesty: honesty at work means spending working hours and resources totally on work.

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  Willingness to learn: this means understanding the way things are done at your work place
and trying to do it better.

 Initiative: being prepared to see what needs doing and to do the work without always being
asked or told to do it.

 Loyalty: do what best for the growth of the organization.

 Maximizing productivity: this is the ability to do high quality work faster and efficiently
The following are ethics we gate from the internship program: -
 We observe group work was better than individual work

 We learn that no need of playing during work

 Saving money and time was must within the work ethics

 We observe safety was first for work

 How we are being punctual for a future

 Being responsibility for a future

4.7 Improving entrepreneurship skills

Entrepreneurship is defined as special human talent that helps manage those factors of production
such as labor machinery and capital and take risks of making loses. An entrepreneur is required to
establish meaningful relationship between activity and authority which is intimately related to
planning function. Entrepreneur a person who create a good opportunity for a new business and
works. Entrepreneurs are very important for the growth of economy. While we was in the factories,
we have got wide knowledge in the entrepreneurship skill that we should have to find our self as
an engineer and creative person by analyzing work opportunities and employee. The major
characteristics of entrepreneurship that we have seen in the factory include: -
 Self-confident: -to be an entrepreneur engineer for the future we should have to be
confident to take positive or negative consequence. In the four moth intern ship programs
leads us to a multi skilled engineer. This skill creates confident in face of difficulties and
discouraging circumstances.

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  Innovative skills: - a good skilled engineer can create a new mechanism in case of a difficult
challenge is occur in the factory. In the four-moth internship program gave us wide hint
how we innovate; if we were subjected to a difficult challenge.

 Results oriented: - to be make successful requires the drive that only comes from setting
goals and targets and getting pleasure from achieving them.

 Total commitment: - hard work and energy are essential elements in the entrepreneur
Profile need to become entrepreneurial.

CHAPTER FIVE
5. CONCLUSION AND RECOMMENDATION
5.1 Conclusion
In general, the four-month industrial internship program allows upgrading student’s practical and
theoretical knowledge. And also improves an inter-personal communication skill among other
individual workers and employees on the hosting company. In addition, the practical activities that
an electrical engineering should have to do when the student are participate in the external world.

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After our four-month industrial internship that we spent on Gondar Malt Factory we have
understood the following issues.
 This internship program also increases student’s self- confidence to take an action and
taking responsibility on the task given to them.

 This internship program enables to us to be hard worker and a success full engineer for
the future because electrical engineering is not only theoretically but also practically.

 Since our country is a collection of different nation nationalities this intern ship program
allows to us how we can familiarize our self with the different cultures and problem of
living and working with group in hosting company.

 Finally, the best program for internship to understand the difference between the theoretical
education in class and what it practically should looks like in the real word.

5.2 Recommendation
The following recommendations are the one that we have understood and visualize while we spent
four-month internship work practice at the Gondar Malt Factory.
 The removals of the dust machine and Compressor installed In this case there is loss of
human power. We recommended that the dust machine and compressor installed at the
ground.

 The distribution panel board installed far from the power plant area due to this there is a
power loss. When the distance between the distribution panel and power plant increase; the
resistance of the cable also increases. Due to this there is a power loss (p=I2*R). We
recommended that the distribution panel and power plant installed at balanced area.

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