METTU UNIVERSITY

FACULTY OF ENGINEERING AND TECHNOLOGY

DEPARTMENT OF ELECTRICAL AND COMPUTER ENGINEERING

STREAM OF INDUSTRIAL CONTROL ENGINEERING

A REPORT ON INTERNSHIP WORK AT ARJO DIDESSA SUGAR FACTORY

BY:

NAME ID.NO.

1. HORDOFA NAGASA RET/2583/08

2. MATIWOS EJIGU RET/2669/08

3. LEMI DEGEFA RET/2648/08

ADVISOR NAME: Mr. DUGASA G.

DURATION OF INTERNSHIP: Oct.2019 - Jan.2020 G.C

SUBMISSION DATE

METTU,ETHIOPIA
 DECLARATION

We certify that this is our original work and all sources of materials used in this internship report
have been fully acknowledged. This internship report is done by advice of our academic advisor
Mr. Dugasa G. and with the help or guidance of our company supervisor Mr. Tadele

Student’s Name ID.NO. Signature

Hordofa Nagasa 2583/08 ________________

Matiwos Ejigu 2669/08 _________________

Lemi Degefa 2648/08 __________________

Advisor’s Name signature Date

Dugasa G. ________________ ___________________

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 ACKNOWLEDGMENT

First of all we would like to thank our God for giving us good health and ability to go through our
internship peacefully and well. Second our families for their love and support throughout our life.

Next, we would like to thank our Mr. Dugasa G. academic advisor, department head Mr. Firew D.
and also all staff members of electrical and computer engineering department for their generous
attitude and friendly behavior.

Thirdly our special thanks to Mr.Tadele (ENG) company plant manager and our advisor for his
personal guidance and supervision. And Mr.Tobarra, Mr.Natan, Mr. Takatal, S/r Zinnu and
Mr.Diriba for their expert guidance, constructive comment and suggestion.

We also thanks to all of the staff members and security guards of ADSF, who treated us with
organizational respect and also helped us with sisterly brotherly relation. We also thank a lot our
friends and well-wishers.

Finally, we apologize all other unnamed who helped us in various ways to have a good training.

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 EXECUTIVE SUMMARY

Industrial training is an important phase of a student life. A well planned, properly executed and
evaluated industrial training helps a lot in developing a professional attitude. The aim and
motivation of this industrial training is to receive discipline, skills, team work and technical
knowledge through proper training environment. The central aim of this study is to attempt the
back ground of the internship hosting company, Arjo Didessa sugar Factory(ADSF), starting with
explaining the brief history of the company and serves. Then tries to discuss about the four-month
general internship experience in different section containing five chapter. The first section deals
with the overall background of hosting company. In second chapter we tried to explain the Work,
Responsibilities and Assignments. Also, we tried to explain the overall benefit gained from the
internship experience that are in terms of improving our practical skill upgrading theoretical
knowledge and so on. Then in next chapter problem identification and proposed a solution. In this
chapter we propose the project on design of microcontroller based induction motor protection by
using voltage sensor, current sensor and temperature sensor interfaced with 16F877A micro-
controller. Sensors are used for sensing the voltage, current and temperature of the environment
and the system displays the output on an LCD.

Lastly, we try to discuss the conclusion and we recommended the problem that is really presented
in the company and activities they must take to solve the problem

III
ACRONYM

AC-Alternative Current

ADC-Analog to Digital Convertor

ADSF –Arjo Didessa Sugar Factory

DC- Direct Current

DOL- Direct On Line

DPT-Differential Pressure Tranismitter

LCD-Liquid Crystal Display

LED-Light Emitting Diode

PID-Proportional Integral Derivative

PLC-Programmable Logic Control

RTD-Resistance Temperature Detector

TCPD-Tone cane per Day

VFD- Variable Frequency Drive

HRI-Human resource institute

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 Contents page
DECLARATION ............................................................................................................................................ I
ACKNOWLEDGMENT ................................................................................................................................. II
EXECUTIVE SUMMARY ............................................................................................................................. III
ACRONYM ................................................................................................................................................ IV
CHAPTER ONE ............................................................................................................................................... 1
1. INTRODUCTION ......................................................................................................................................... 1
1.1. Company Background and Over Views .............................................................................................. 1
1.2 Vision, Mission, Values and Objectives of ADSF ................................................................................. 2
1.2.1 Vision............................................................................................................................................ 2
1.2.2 Mission ......................................................................................................................................... 3
1.2.3 Value ............................................................................................................................................ 3
1.3 Objective of ADSF................................................................................................................................ 3
1.4 Product of the Company ..................................................................................................................... 3
1.5 Customers of Company ....................................................................................................................... 3
1.6 Organizational structure of ADSF........................................................................................................ 4
1.7 Staff Profile ......................................................................................................................................... 5
CHAPTER TWO .............................................................................................................................................. 6
2. WORK, RESPONSIBILITY AND ASSIGNMENTS............................................................................................ 6
2.1 Introduction ............................................................................................................................................ 6
2.2 Procedures used while Performing Tasks ............................................................................................... 6
2.2.1 Task One (rewinding failed motor) .................................................................................................. 6
2.2.2 Task Two (Electric machines and Instrumentation's identification) .............................................. 10
2.2.2.1 Electric Motor (induction motor) ............................................................................................ 10
2.2.2.2 Motor Starting Mechanisms ................................................................................................... 10
2.2.2.3 Sensor...................................................................................................................................... 11
2.2.2.4 Controller ................................................................................................................................ 12
CHAPTER THREE .......................................................................................................................................... 14
3. TECHNICAL ASPECTS OF THE INTERNSHIP .............................................................................................. 14
3.1 Introduction .......................................................................................................................................... 14
3.2 Objective ............................................................................................................................................... 14
3.2.1 General objective ....................................................................................................................... 14
3.2.2 Specific Objective of Internship Program .................................................................................. 14
3.3 Methods and Procedures ...................................................................................................................... 15
3.3.1 Processing .................................................................................................................................. 15
3.3.2 Energy in the sugar mill .............................................................................................................. 18
3.4 Components in Internship Area ............................................................................................................ 24
3.4.1 Three phase squirrel cage Induction.............................................................................................. 24
3.4.2 Variable Frequency Drive (VFD) ..................................................................................................... 25
3.4.3 Air Conditioning ............................................................................................................................. 27
3.4.4 PID controller ................................................................................................................................. 28
3.4.5 Steam turbine ................................................................................................................................ 29
3.5 Technical tasks/products ...................................................................................................................... 30
3.6 knowledge and acquaintances acquired............................................................................................... 31
3.6.1 Technical Skill Gained..................................................................................................................... 31
3.6.2 Management Skills Gained ............................................................................................................ 32
3.6.3 Acquaintances Acquired ................................................................................................................ 32
3.7 Contribution .......................................................................................................................................... 32
CHAPTER FOUR ........................................................................................................................................... 34
4. GENERAL COMMENTS AND CONCLUSION .............................................................................................. 34
4.1 Problem encountered during the internship period............................................................................. 34
4.2 General Suggestions and Comments to the Company ......................................................................... 35
4.3 Summary and Conclusion ..................................................................................................................... 36
CHAPTER FIVE ............................................................................................................................................. 37
5. PLC BASED AUTOMATIC TEMPERATURE AND WATER LEVEL CONTROL SYSTEM FOR BOILER
PROTECTION ............................................................................................................................................... 37
5.1 INTRODUCTION ..................................................................................................................................... 37
5.2 Statement of problem........................................................................................................................... 37
5.3 Objective ............................................................................................................................................... 38
5.3.1 General objective ........................................................................................................................... 38
5.3.2 Specific objective ........................................................................................................................... 38
5.4 methodology ......................................................................................................................................... 38
5.4.1 Block diagram................................................................................................................................. 39
5.4.1.1 Block diagram description....................................................................................................... 39
5.4.2 System flow chart .......................................................................................................................... 40
5.4.2.1 Overall flow chart description................................................................................................. 42
 5.4.3 Assignment of input/output and ladder diagram development ............................................... 43
5.5 RESULTS................................................................................................................................................. 44
5.6 CONCLUSION AND RECOMENDATION .................................................................................................. 50
5.5.1 Conclusion ...................................................................................................................................... 50
5.5.2 Recommendation........................................................................................................................... 51
REFERENCES ................................................................................................................................................ 52
APPENDIX .................................................................................................................................................... 53
List of figures
Figure 1: Arjo Didessa Sugar Factory (ADSF) ............................................................................................. 2
Figure 2: Organizational Structure................................................................................................................ 4
Figure 3: Failed rewinded motor ................................................................................................................... 7
Figure 4: Architecture of PLC .................................................................................................................... 13
Figure 5: Mill house .................................................................................................................................... 16
Figure 6: Block diagram of sugar processing ............................................................................................. 19
Figure 7: program logic controller .............................................................................................................. 23
Figure 8: Three phase induction motor ....................................................................................................... 24
Figure 9: Variable frequency drive (VFD) ................................................................................................. 25
Figure 10: working principle of variable frequency drive (VFD)............................................................... 27
Figure 11: Air conditioner (ac) ................................................................................................................... 28
Figure 12: Working of PID Controller........................................................................................................ 29
Figure 13: steam turbine ............................................................................................................................. 29
Figure 14: methodology of the project ........................................................................................................ 39
Figure 15: overall Block diagram of the system ......................................................................................... 39
Figure 16: Overall flow chart of the system ............................................................................................... 42
Figure 17: When level is low (a) and (b) .................................................................................................... 45
Figure 18: When level is high ..................................................................................................................... 46
Figure 19: When level is high and temperature is low................................................................................ 47
Figure 20: When both level and temperature are low ................................................................................. 48
Figure 21: When level is low and temperature is high................................................................................ 49
List of Tables
Table 1: Full information about failed motor................................................................................................ 8
Table 2: material used for winding ............................................................................................................... 9
Table 3: Input/output assignment of level sensor ....................................................................................... 43
Table 4: Input/output assignment of temperature sensor ............................................................................ 43
 CHAPTER ONE

1. INTRODUCTION

1.1. Company Background and Over Views

Arjo Didessa sugar factory is located in the western part of the country, Oromia National Regional
state, East Wellega, Bunno Bedelle and Jima zones within Didessa valley. It’s located at 395km
distance from Addis Ababa- Nekemte -Bedelle -Jimma route. It is one of the sugar factories and
sugar development projects that are given due attention by our developmental and democratic
government. The total concession area of the factory is about 50 thousand hectares and 49 kebeles
of east Wellega, Bunno Bedelle and Jima zones are included within its command area. Generally
the climate and the soil around the command area of the factory are suitable for sugar cane
production [1].

The Arjo Didessa sugar factory was first established by individual person who called Hajji Margie
paradise in 2001 E.C and his citizenship is Pakistan. His purpose is to increase the economic
development by producing sugar, using the modern technology. In 2003 produce some sugar, but
fully not succeeded his work and then he sold his factory to the Ethiopian Democratic Government
in 2005 E.C. Arjo Didessa sugar factory, previously called Al -Habasha sugar mills and
established by Pakistan investor and was transferred to FDRE Sugar Corporation and commenced
operation . The erection of the factory was completed by 90 percent when the factory was
transferred to FDRE government. During the current budget year the remaining 10 percent of the
erection of the factory was completed and the factory commenced production of refined sugar as
of April, 2007 [1].

The produced sugar is refined and meets export standard, so that our country will earn foreign
currency by exporting it for world market.

The factory has the crushing capacity of 8000 tone cane per day (TCD). The factory can have the
crushing capacity of 12000 TCD by further improving its design capacity in the future. The source
of the water for irrigation is Didessa River and river side dam construction is under way by Oromia

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water works enterprise. Currently, about 2729 hectares is planted and covered by sugar cane
plantation.

Some important factors that make Arjo Didessa sugar factory different from other sugar factories
[1];

 It’s the only factory that produced refined sugar

 It’s the only factory that own wood chipper. Two wood chippers that are found in the
factory easily prepare woods that are needed as a fuel for boilers.
 Auxiliary cane carriers are under ground
 No prewashing of cane
 The factory is found by the side of the asphalte Nekemte-Bedelle route
 Cane handling, cane conveying and cane preparation units operates hydraulically and
this makes cane preparation operation is very easy

Figure 1: Arjo Didessa Sugar Factory (ADSF)

1.2 Vision, Mission, Values and Objectives of ADSF

1.2.1 Vision

Ensuring sustainable growth and became one of rather ten competitive sugar producing countries
of the world in 2023 [1].

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1.2.2 Mission

 Building human capital and modern technology that would enable to utilize the potential
resources of the country for development.
 Produce sugar co-products and make use of the by-products and satisfy the local demand
and insuring the benefit of people there by support the development of the country seizing
significant export share [1].

1.2.3 Value

 Sustainable change and competitiveness

 Ethical
 Productivity is the base of their existence
 Serving the public interest
 Continuous learning
 Encouraging captivity and work excellence [1].
1.3 Objective of ADSF

Arjo Didessa sugar factory is a public enterprise established in accordance with Ethiopian
government to under taken the following objectives;
 To plan and growth sugar cane.
 To carry on specific Industrial and Agricultural research and surveys.
 To study plan and implement various sugar development programs
 Produce white sugar (Refining sugar).
 Create direct job opportunities for citizens [1].

1.4 Product of the Company

The main products of Arjo Didessa sugar Factory (ADSF) is the refined (white) sugar.

1.5 Customers of Company

Arjo Didessa Sugar Factory produces high quality of white sugar for its customers. The customers
these factories are:-

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  National liquor factory
 Pharmaceutical factory
 Different soft drinks factory such as:-
 Bedelle brewery factory
 Ambo mineral water and etc.
 Workers of the company.

1.6 Organizational structure of ADSF

The enterprise has adapted a team management style and the structure comprises five broad
sectors, namely, agricultural operations, factory operations, planning project, human resource and
finance and supply as shown in chart below [2].

Figure 2: Organizational Structure

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1.7 Staff Profile

As we have collected information from HRI about staff profile of ADSF currently, it is carried out
multi-furious activities and creates job opportunity for 1000 permanent and 1750 contract and
seasonal workers. It has played its share in efforts exerted to eradicate poverty by making the
community beneficially of all available opportunities. Apart from these about 200 people drown
from the local community being organize under 20 micro and small scale enterprises and provide
different services to users. They are striving to bring change to their life.

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 CHAPTER TWO

2. WORK, RESPONSIBILITY AND ASSIGNMENTS

2.1 Introduction

In the internship process facilitated for us by our university we have tried to catch up every possible
knowledge and experiences that is available in hosting company Arjo Didessa Sugar Factory
(ADSF).

2.2 Procedures used while Performing Tasks

The main procedures that we have been using while performing tasks are:

 First, Observing different section of the factory. In each section, factory workers,
technicians and machines operator explain the part of the machine, function and operating
system of the machine found in each section.
 Second, collecting data from various sources (like manuals, by asking technicians and
operator and from name plates of machines).
 Third, discussion, identifying the problem (if any) found on each machine.
 Forth, analysis and suggest [2].

2.2.1 Task One (rewinding failed motor)

In this section we have observed how electrical machines (Motors) are rewinded. In the rewinding
procedure we tried to present how we rewind Motor which is failed during operation.

Objective

To rewind failed electrical motor during operation and constructing as it comes from manufactured
company.

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Rewinding procedure

Firstly, what we have done in the winding section is to observing and close looking at how any
electrical motor can be rewind and also we get the opportunity to see when an induction motor is
being rewind by the rewinding section staff.

Secondly, we see that how we can get the information from the failed motor nameplates. Like,
number of turn required, coil diameter, type of winding, coil group and phase apart. By
understanding all this information we have given to rewind another electrical motor. Here is the
procedure how we rewind the given failed Motor.

Figure 3: Failed rewinded motor

We take all necessary data from the failed motor as shown below.

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Table 1: Full information about failed motor

No Data Specification Remark

1 Voltage rating 380V

2 Current rating 3.3A

3 Power rating 1.5 KW

4 Number of slot 24

5 Number of pole 2

6 Number of coil group 4

7 Wire size 0.65mm

8 Phase apart 8

9 Jumper 12

10 No of slot per pole per phase 3

11 Type of winding Concentric

12 Number of turn 56

13 Frequency 50 Hz

2. Next what we have done is to look for materials like wire with the required diameter and other
material for rewinding the machine. The following are lists of material used in the winding.

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Table 2: material used for winding

No Material Specification Remar

k

1 Copper wire 0.65mm

2 Varnish For insulation

3 Wedge

4 Insulation paper For insulation

5 Insulation tube For insulation

6 Solder and soldering For strength and to resist

3. The next step is preparing the coil as the required number of turn and length of the stator have
in measured and adjust the length of the coil to be good enough to put it in the slot.

4. After this, we have done to put insulation paper in the slot and we put the coil in the slot
according to their proper place. We have also put the wedges so that the coil will not escape the
stator. The wedges also protect the coil from mechanical damage from the rotor during operation.

5. After finishing the above step, we made all group connection and we have checked the motor:

 For continuity
 For insulation
 Ground test
 Open circuit test and
 coil resistance circuit

6. Lastly, we have insulated by the use of insulation varnish winding and checking all electrical
Connection. Then we put the rotor back to its position and tested well again.

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Finally, the rewinded motor is worked well.

2.2.2 Task Two (Electric machines and Instrumentation's identification)

The main electrical equipment’s that we have seen and tried to know how they are connected to
function the plant in the companies are: Transformers, Motors, Generator, Sensors, and Contactors,
Relays, PLC, Converters, Inverters, Filters, Capacitors and Resistor /bigger in size/. From these
listed above we have seen some of them roughly.

2.2.2.1 Electric Motor (induction motor)

A world without electric motors is difficult to imagine. Motors are used in many diverse
applications. There are a multitude of motor types to choose from. Each has its own unique
characteristics, making one motor type a better choice for an application than another. All motors
classified based on the power they drive, alternating current (AC) or direct current (DC). Based on
this motor classified as AC motors (Induction) and DC motors. In ADSF the motor used are almost
three phase induction motors and few servo motors [3].

Induction motors

In the company induction motors are used from the beginning until the end of the process. The
motor varies depending on the usage and the ratings from high rating motors for the milling process
and low rating motors for conveyor belts.

Advantages of induction motors

 Simple control gear for starting and speed control.

 Easy operation and simple maintenance.
 Rugged construction.
 Simple design and reliable.
 Cost effective

2.2.2.2 Motor Starting Mechanisms

In Arjo Didessa Sugar Factory, there are lots of motors having different starting mechanisms for
continuous operations like direct-on-line starting (DOL), star-delta starting (S/D), resistor starting
10
(wound rotor starting), soft starting, pole change starting and variable frequency driving (VFD)
starting. Even if the company uses those starting mechanisms the most frequently operated
mechanisms are Star- delta and variable frequency driving (VFD).

2.2.2.3 Sensor

We live in a world of sensors. A sensor is an input device which provides an output (signal) with
respect to a specific physical quantity (input). And it is a device that converts signals from one
energy domain to electrical domain [3]. There are different types of sensors used in ADSF, which
we come across are:

Temperature Sensor

Temperature sensor is one of the most common and most popular sensors. A temperature Sensor,
used to measure the changes in the temperature. These changes correspond to change in its physical
property like resistance or voltage. The products in the ADSF Company are very sensitive to the
change in temperature. Smaller change in temperature can cause a serious damage both to the
product and the machine, so for the company controlling the temperature is something very critical.
These sensors are used in the mixing, refining and amalgamation process, the temperature variance
is controlled over the control panel provided. From the type of temperature sensor, Resistant
temperature detector (RTD), Thermistor and thermocouple temperature sensor mostly [3].

Pressure sensor

It is a device used for pressure measurement of gases, liquids or steam. Pressure is an expression
of the force required to stop a fluid, steam or gaseous from expanding, and usually stated in terms
of force per unit area that a substance exerts on its surrounding.

In the ADSF they used compressed air for production process. Thus, the flow of the air or steam
measured and controlled for desirable output. Here the pressure sensor is used in conjunction with
the venture or vacuum pump effect. So, the pressure sensor that we have seen in ADSF are pressure
gauge, vacuum pressure gauge, deferential pressure transmitter(DPT),water flow pressure
transmitter, steam flow transmitter, furnace pressure transmitter and drum level transmitter and so
on [3].
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Speed Sensors

Speed sensor is widely used for measuring the output speed of a rotating object. There are many
types using different principle and most of them produce an electrical output. In industries there
must be a motor, if there is a motor there is motion or rotating objects in process of manufacturing.
The speed of rotary parts controlled by the help of the speed sensor [3]. In order to have a desire
output the speed of any rotating machine parts must be maintain to its optimum speed. The speed
of the in-feeding belts and the out-feeding belts must be maintained at optimum speed for desirable
machine performance and safe operation of the lines.

Level Sensor

Level sensors should not connect with the outlet pipe of a vessel as this can subtract the velocity
head from the reading while fluid is flowing. Level sensors should be placed in a still part of the
vessel, such as after a weir, and/or away from liquid outlets or vapor inlets. When inlet and outlet
valves are placed at the ends of the drum, the least agitated liquid region will, however, be at the
center of the drum which is therefore the best location for sight-gauge glasses and level controllers.
However, it is good practice to put level gauges at the drain-point end and reduce turbulence by
use of a stilling tube. The pressure gauge connection should always be placed in the vapor
headspace above the liquid in the drum, and located so that the face of the pressure gauge is visible
from the ground or platform.

2.2.2.4 Controller

Programmable logic controller (PLC)

It is a microprocessor-based system that uses programmable memory to store instructions and

implement functions such as logic, sequencing, timing, counting and arithmetic in order to control
machines and processes.

Some PLC Features are [3]:

 They are rugged, withstand industrial environment, such as heat, humidity, mechanical
shocks and vibrations.
 The interfacing for inputs and outputs is inside the controller.
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  They are easily programmed.
 PLC is capable of both logic and PID control [4].

Figure 4: Architecture of PLC

Input/output unit of PLC

The input/output unit provides the interface between the system and the outside world. The input/
output interface provides isolation and signal conditioning functions. So, that sensors and actuators
can often be directly connected to them without the need for another circuitry. Output devices are:
motors, starting coils, solenoid valve, etc. And input devices are: temperature sensors, microphone,
pressure sensor and etc.

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 CHAPTER THREE

3. TECHNICAL ASPECTS OF THE INTERNSHIP

3.1 Introduction

From our internship program we have gained so many benefits which are very important for our
basis of knowledge and lead us good experience for the future, as well as good opportunity for
different occupation

The industrial internship report that we have written is on greater detail contains (includes) the
fundamental job and activities that we had able to model it as tangible activities and Performance.
We also recorded various activities that we are able to perform them by our self at the time of
internship duration.

In addition to these, different activities that we have seen in the company by our supervisor and
mentor were included. Thus according to Arjo Didessa sugar factory the production process flow
of the factory is throughout in many processes.

3.2 Objective

3.2.1 General objective

The objectives of this internship program is believed to introduce us to get methods of problem
solving and gaining practical skills.

3.2.2 Specific Objective of Internship Program

We got real world experience or practical knowledge from internship program which we haven’t
gained before. Those are:-

 Developed practical skills from internship semester training

 We got leadership skills

 Exercised the work ethics

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  Upgraded theoretical knowledge that we have learned before

3.3 Methods and Procedures

We have learned the process of sugar production starting form cane field to the end of product.
These processes are described briefly.A sugar cane mill is a factory that processes sugar cane to
produce raw or white sugar .The term is also used to refer to the equipment that crushes the sticks
of sugar cane to extract the juice [2].

3.3.1 Processing

There are a number of steps in producing raw sugar from cane:

1. Cane receiving and unloading (receive the cane at the factory and unload it from the
transport vehicles)
2. Cane preparation (cutting and shredding cane to prepare it for juice extraction)
3. Juice extraction (two technologies are in common use; milling or diffusion)
4. Juice clarification (remove suspended solids from the juice, typically mud, waxes, fibers)
5. Juice evaporation (to concentrate the juice to a thick syrup of about 65° brix )
6. Syrup clarification (remove suspended solids from the syrup, typically colloid size of mud,
waxes, fibers, etc.)
7. Crystallization
8. Centrifugation (Separation of the sugar crystals from the mother liquor, done by centrifugal
machines)
9. Sugar drying
10. Packaging and delivery

These processing steps will produce a brown or raw sugar. Mill white sugar also known as
plantation white sugar can be produced by introducing some form of colour removal process (often
sulphitation) between the juice clarification and the juice evaporation stages mentioned above. The
raw sugar produced is often refined to produce white sugar. This sugar refining can be done either
at a completely separate factory or at a back-end refinery which is attached to the raw sugar factory.

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There are two processes for extracting juice from cane:

 Milling, and
 Diffusion

3.3.1.1 Milling

Juice extraction by milling is the process of squeezing the juice from the cane under a set mills
using high pressure between heavy iron rollers. Those mills can have from 3 up to 6 rolls; every
set of mills is called a tandem mill or mill train. To improve the milling extraction efficiency,
imbibition water is added at each mill.

Hot water is poured over the cane just before it enters the last mill in the milling train and is
recirculated up to reach the first mill. The juice squeezed from this cane is low in sugar
concentration and is pumped to the preceding mill and poured onto the cane just before it enters
the rollers, the juice from this mill is the same way pumped back up the milling train. Mixed juice
(that is to say cane juice mixed with the water introduced at the last mill) is withdrawn from the
first and second mills and is sent for further processing. Milling trains typically have four, five or
six mills in the tandem. To improve the milling extraction performance before the cane reaches
the first mill, knife and shredder preparation equipment is normally used.

Figure 5: Mill house

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3.3.1.2 Diffusion

Sugarcane diffusion is the process of extracting the sucrose from the cane with the use of
imbibition but without the squeezing by mills. Shredded cane is introduced into the diffuser at the
feed end, Hot water is poured over the shredded cane just before the discharge end of the diffuser.
The hot water percolates through the bed of cane and removes sucrose from the cane. This dilute
juice is then collected in a compartment under the bed of cane and is pumped to a point a little
closer to the feed end of the diffuser and this dilute juice is allowed to percolate through the bed
of cane. At this point the concentration of sucrose in the cane is higher than the concentration of
sucrose in the dilute juice just mentioned and so sucrose diffuses from the cane to the juice, this
now slightly richer juice is pumped back up the diffuser and the process is repeated, typically, 12
to 15 times (compared with the four to six times for the milling process)

3.3.1.3 Juice clarification

Sugar cane juice has a pH of about 4.0 to 4.5 which is quite acidic. Calcium hydroxide, also known
as milk of lime or limewater, is added to the cane juice to adjust its pH to 7. The lime helps to
prevent sucrose's decay into glucose and fructose. The limed juice is then heated to a temperature
above its boiling point. The superheated limed juice is then allowed to flash to its saturation
temperature: this process precipitates impurities which get held up in the calcium carbonate
crystals [5]. The flashed juice is then transferred to a clarification tank which allows the suspended
solids to settle. The supernatant, known as clear juice is drawn off of the clarifier and sent to the
evaporators.

3.3.1.4 Juice evaporating

The clarified juice is concentrated in a multiple-effect evaporator to make a syrup of about 50

percent sucrose by weight.

3.3.1.5 Crystallization and centrifuging

A number of boiling schemes are possible, the most commonly used boiling scheme is the three-
boiling scheme. This method boils the sugar liquors in three stages, called A-, B- and C-.

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A batch type sugar centrifuge separates the sugar crystals from the mother liquor. These
centrifuges have a capacity of up to 2,200 kilograms (4,900 lb) per cycle. The sugar from the
centrifuges is dried and cooled and then stored in a silo or directly packed into bags for shipment.

The mother liquor from the first crystallization step (A-product) is again crystallized in vacuum
pans and then passed through continuous sugar centrifuges. The mother-liquor is again crystallized
in vacuum pans. Due to the low purity the evapo-crystallization alone is not sufficient to exhaust
molasses , and so the so-called massecuite (French for “boiled mass”) is passed through cooling
crystallizers until a temperature of approx. 45 °C (113 °F) is reached. Then the massecuite is re-
heated in order to reduce its viscosity and then purged in the C-produced centrifugal.

The run-off from the C-centrifugal is called molasses. The spun-off sugar from the B-product and
C-product centrifuges is re-melted, filtered, and added to the syrup coming from the evaporator
station. Crystallization process not only removes dissolved sucrose from solution and recovers it
as solid sucrose crystals, but it is also a very powerful purification process.

3.3.1.6 Back-end refineries

Some cane sugar mills have so-called back-end refineries. In back-end refineries, raw sugar
produced in the mill is converted to refined sugar with a higher purity for local consumption,
export, or bottling companies. Wastage is used for heat generation in the sugar mills.

3.3.2 Energy in the sugar mill

The remaining fibrous solids, called bagasse, are burned for fuel in the mill's steam boilers. These
boilers produce high-pressure steam, which is passed through a turbine to generate electrical
energy (cogeneration).

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The exhaust steam from the turbine is passed through the multiple effect evaporator station and
used to heat vacuum pans in the crystallization stage as well as for other heating purposes in the
sugar mill. Bagasse makes a sugar mill more than energy self-sufficient; surplus bagasse goes in
animal feed, in paper manufacture, or to generate electricity for sale.

Figure 6: Block diagram of sugar processing

Cane Yard: In this area unloading and cane preparation will takes place using cane table, main
cane carrier, levelers, two sets of knives, shredder and magnetic separator.

Weight Bridge: is a large scale usually mounted permanently on a concrete foundation that are
used to weight entire vehicles (trucks) and their contents. By weighting the truck both empty and
when loaded then the load carried by truck can be calculated. The key component that uses a
weight bridge in order to make the weight measurement is load cell.

Load cell: is a transducer that is used to convert a force into electrical signal. This conversion is
in direct and happens in two stages through mechanical arrangement. The force sensed deforms a
strain gauge. The strain gauge measures the deformation as an electrical signal because the strain

19
changes the effective electrical resistance of wire. A load cell usually consists of four strain gauges
in a wheat stone bridge configuration.

The electrical signal output is typically in order of mill volts and requires amplification by an
instrumentation amplifier. Before it can be used the output of transducer is plugged into calculate
the force applied to the transducer.

Unloading: Unloading is one part of the system used in Arjo Didessa sugar factory, which used
to load a cane which comes from the field and transmit it into the cane table. During this process
takes place, we are focused on the electrical control and the operation of unloading

Feed (cane) table: Cane table is a table which made from hard metal and used to transfer the cane
into main cane carrier by controlling its speed. It is in effect a very wide and short carrier driven
by an independent motor.

The ADSF has three feed tables at the two sides of the cane carrier. The crane deposits the cane
on this table and keeps up the supply to it as it discharges. The cane deposited at feed table falls in
to the cane carrier.

Main cane carrier: main cane carrier is a plant that is used to carry a cane and transmit the cane
into the cane knives.

Cane knives: Is a piece of equipment which is used to cut the cane in very short and small pieces.
The cane knives perform two functions and have two advantages:

 They favor the capacity of the mill.

 They assist the extraction of the mills by breaking the rind of the cane and so facilitating
its disintegration and the extraction of its juice.

ADSF uses two knives each of which uses wound rotor ac motor. The first knives are the leveler
knives which are required mainly to even out the layer of cane.

They are arranged to work with a high clearance and in consequence leave a large portion of uncut
cane. The second knives are used at a very small clearance and have the function of finishing the
complete disintegration of the cane. They also cuts the lower layer which the first set has not
touched and delivers the cut cane in smaller and thinner pieces. The speed of rotation of a knife
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set varies from 400-720rpm.The speed most frequently used in ADSF is 600rpm for the first set
of knife and second set of knife. Thus they facilitate the feeding of the mill.

Shredder: The objective of the shredder is to complete the preparation and disintegration of the
cane, so as to facilitate the extraction of the juice by the mills. It establishes a state of subdivision
of the cane which greatly facilitates the work of the mills, and it has a hammer that is used for
hitting the cane. The shredder thus consists a rotor working at 500, 1000 or 1500rpm.But in case
of ADSF, generally it works at 800-900rpm and controlled manually via governor motor.

Milling: is the process by which pressure is applied to the prepared cane to extra as much juice as
possible from it. The cane is made to pass through a succession of rollers that comprises the milling
tandem, and its juice is squeezed out as it goes through. To help to extract the maximum juice, use
of imbibition water is made. The extracted juice is sent to process and the fibrous material left after
milling, known as final bagasse, is sent to the boilers to be used as fuel for the generation of steam.

Mixed juice: Mixed juice from the milling tandem contains a large amount of cane fiber that falls
out with the juice between the rollers of the mills. All juice prepared in each five milling is pumped
by the motor and inter to the mixed tank. The juice identified from bagasse is moved by the motor
and pass to the defecation room. It has two motors which contain the power 110kw with the speed
of motor 1485rpm.

Defecation room: These rooms are take juice from mixed and add lime to the juice. It has two
motors to send juice for sugar research institute. The motor power is 110kw with speed of
1485rpm.

Sugar research institute: At this room sugar is must be studied. Means filter cake and cleared
juice separated. There are four motors which have the power 30kw with speed of 1460rpm for
each of them. S.R.I is sending the juice to the vapors’ room.

Vapors room: The process of evaporator is to remove part of water from the clarified juice. At
this place the juice is vaporized at different pressure and temperature by using the steam energy
and send to the supplier tank by the motors.

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The main purposes of evaporators are:-

 To evaporate the water to the concentrate the sucrose as the water evaporates from the juice
the viscosity of the juice increases.
 It is concentrating juice from about 15oBrix to 60-65 bricks.
 Also the temperature has to be controlled. Once this is done, the juice is thickness up in to
syrup by boiling off water using steam in a process called evaporation

Supplier Tank: These are storage (buffer) tanks for syrup, molasses and wash liquors from which
feeding to pans is done. Their position can be at higher or equal elevation with pans. Feeding from
the tanks to pans is with the help of vacuum. Most of the time, these tanks are rectangular boxes
with open top. The number and capacity of the tanks depends on the flow rate of the liquors or
factory rate and the retention time required in the tanks .Supply tanks are insulated to minimize
heat loss from the liquors.

Syrup: Syrups are a concentrated solution of a sugar mixed in water or other aqueous liquid. A
mixture of appropriate purity of syrup and/or running is fed to the pan until the calandria is just
covered. The juice is converted to the continuous centrifugal by the motor which have power
110kw with speed of 1485rpm.

A continuous centrifugal: In continuous centrifugal machines sugar and molasses extraction and
color formation of sugar processed, and a machine which will continuously separate sugar from
massecuite (a dense mass of sugar crystals mixed with mother liquor obtained by evaporation). It
has 22 motors. The 11 motors are 75kw with the speed of 1480 rpm and11 motors are 90kw with
the speed of 1480rpm.

Molasses: Molasses also called treacle, syrup remaining after sugar is crystallized out of cane or
beet juice. Molasses syrup is separated from sugar crystals by means of centrifuging. Molasses is
separated from the sugar crystals repeatedly during the manufacturing process, resulting in several
different grades of molasses; that obtained from the first extraction contains more sugar, tastes
sweeter, and is lighter in colour than molasses obtained at the second or third extractions.

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The lighter grades of molasses made from sugarcane are edible and are used in baking and candy-
making and to make rum. The molasses obtained from sugar beets has a very low sugar content
and is generally inedible.

Refinement room: Clarified sugar is completely converted into be white sugar.

Batch centrifugal: It is used to sieve the massecuite into mother liquor (the part of a solution that
is left over after crystallization) and sugar crystal with the advantage of centrifugal force found by
rotating the massecuite carrying basket .the drive system utilizes a variable frequency drive with
a sequence controlling mechanism of PLC (programmable logic control). Batch centrifugal
machine is controlled by using variable frequency drive .which means that its speed is varied with
frequency. Under this activity also practiced on instruments used to driven the machine. High
grade sugar can be processed by using batch centrifugal.

PLC (program logic controller); Over all operation of handling and bagging is controlled by
PLC by adjusting the timer to discharging and brake solenoid valve to open and closes cylinder.

Figure 7: program logic controller

Sugar handling: This the last process of sugar production the electrical instrument they use in
ADSF is for bagging is four load cell which is used to measure the weight of sugar in the case of
ADSF the weight is set to be 50KG accordingly, then inductive proximity sensor used to senses
the metal to open and closes the bagging; discharging and brake solenoid valve to open and closes
the cylinder.
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Sugar Bagging: A place where, when the final product of dried sugar is sent for packing.

3.4 Components in Internship Area

There are a lot of components that we are faced during we stayed in factory.eg But we cannot
define all of them completely. So, let we describe some them with their working principle.

3.4.1 Three phase squirrel cage Induction

This Motor is one of the most popular types of AC electric motor which achieve the
electromechanical energy conversion through stator and squirrel cage rotor by electromagnetic
induction. That’s why it’s called squirrel cage induction motor.

Normally, we use this motor in industrial drives because they are rugged, reliable and economical.
By the way, the induction motor is also called an asynchronous motor because it runs at a speed
lower than its synchronous speed. In this article, we are going to focus on the working principle of
the induction motor.

Figure 8: Three phase induction motor

How a 3 phase squirrel cage Induction Motor Works?

Actually, when we give the stator winding AC power supply, the current flow in the coil will
produce a magnetic flux in the coil. Now, set the rotor windings to short circuit. The flux from the

24
stator will cut the coils in the rotor, and the Faraday’s law of electromagnetic induction will cause
the current to flow in the coil of the rotor due to the short circuit of the rotor coil. The stator and
rotor current flow produces two fluxes, one is the stator flux and the other is the rotor flux, and the
rotor flux will lag behind the stator flux. Thus, the rotor will feel the torque that rotates the rotor
in the direction of the rotating magnetic flux. Therefore, the speed of the rotor will depend on the
AC power, and the speed can be controlled by changing the input power. Inherent slip – unequal
rotation frequency of stator field and the rotor. A three-phase power supply provides a rotating
magnetic field in an induction motor.

3.4.2 Variable Frequency Drive (VFD)

A Variable Frequency Drive (VFD) is a type of motor controller that drives an electric motor by
varying the frequency and voltage supplied to the electric motor. Frequency (or hertz) is directly
related to the motor’s speed (rpms). If an application does not require an electric motor to run at
full speed, the VFD can be used to ramp down the frequency and voltage to meet the requirements
of the electric motor’s load. As the application’s motor speed requirements change, the VFD can
simply turn up or down the motor speed to meet the speed requirement [3].

Figure 9: Variable frequency drive (VFD)

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How does a Variable Frequency Drive work?

The first stage of a Variable Frequency AC Drive, or VFD, is the Converter. The diode bridge
converter that converts AC-to-DC, is sometimes just referred to as a converter. The converter that
converts the dc back to ac is also a converter, but to distinguish it from the diode converter, it is
usually referred to as an “inverter”. It has become common in the industry to refer to any DC-to-
AC converter as an inverter. Note that in a real VFD, the switches shown would actually be
transistors or thyristors. When we close one of the top switches in the inverter, that phase of the
motor is connected to the positive dc bus and the voltage on that phase becomes positive. When
we close one of the bottom switches in the converter, that phase is connected to the negative dc
bus and becomes negative. Thus, we can make any phase on the motor become positive or negative
at will and can thus generate any frequency that we want. So, we can make any phase be positive,
negative, or zero. The output from the VFD is a “rectangular” wave form. VFD’s do not produce
a sinusoidal output. This rectangular waveform would not be a good choice for a general purpose
distribution system, but is perfectly adequate for a motor.

Why should we use a VFD?

 Reduce Energy Consumption and

 Energy Costs(If you have an application that does not need to be run at full speed, then you
can cut down energy costs by controlling the motor)
 VFDs allow you to match the speed of the motor-driven equipment to the load requirement.
 Can reduce energy consumption in your facility by as much as 70%.
 Improves product quality
 Increase Production Through Tighter Process Control
 By operating your motors at the most efficient speed for your application, fewer mistakes
will occur, and thus, production levels will increase.

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 Figure 10: working principle of variable frequency drive (VFD)

3.4.3 Air Conditioning

A system for controlling the humidity, ventilation and temperature in a building or vehicle,
typically to maintain a cool atmosphere in warm conditions.

Air Conditioner Working Principle

An air conditioner continuously draws the air from an indoor space to be cooled, cools it by the
refrigeration principles and discharges back into the same indoor space that needs to be cooled.
This continuous cyclic process of drawl, cooling and recalculation of the cooled air keep the indoor
space cool at the required lower temperature needed for comfort cooling or industrial cooling
purpose. When you switch the air conditioner on, the thermostat control sends 120V of alternating
current to the compressor and the fan motor. The compressor act as a pump compressing the
refrigerant in gas form into the condenser coils. Located the back of the unit. Where the gas is
condensed into a hot liquid. The condenser coils dissipate the heat as the liquid travels through
them.Once the liquid refrigerant has passed through the condenser coils and the capillary tube
where it undergoes expansion. The liquid refrigerant passes through the evaporator coils. It travels
to the evaporator coils located near the front of the unit.

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As the refrigerant liquid enters these coils it expands into a gas which makes the coils cold. The
gas flows through the coils to a suction line, attached to the compressor the compressor converts
the gas back into a liquid and the cooling cycle continues.

Figure 11: Air conditioner (ac)

3.4.4 PID controller

PID controller consists of three terms, namely proportional, integral and derivative control. The
combined operation of these three controllers gives control strategy for process control. Some of
the applications use PID controllers in cascade networks where two or more PID’s are used to
achieve control.

Instrument used in industrial control applications to regulate temperature, flow pressure, speed and
other process variable.it uses a control loop feedback mechanism to control process variables n
are the most accurate and stable controller.

Working of PID Controller

With the use of low cost simple ON-OFF controller only two control states are possible, like fully
ON or fully OFF. It is used for limited control application where these two control states are
enough for control objective. However oscillating nature of this control limits its usage and hence
it is being replaced by PID controllers. PID controller maintains the output such that there is zero
error between process variable and set point/ desired output by closed loop operations. PID uses
three basic control behaviors that are explained below.

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 Figure 12: Working of PID Controller

3.4.5 Steam turbine

The steam turbine is one kind of heat engine machine in which steam's heat energy is converted to
mechanical work. It consists of a rotor and a set of rotating blades which are attached to a shaft
and the shaft is placed in the middle of the rotor. The turbine generator collects the mechanical
energy from the shaft and converts it into electrical energy. Steam turbine generator also improves
the turbine efficiency.

Figure 13: steam turbine

Working Principle of Steam Turbine

Working principle of steam turbine depends on the dynamic action of steam. A high-velocity steam
is coming from the nozzles and it strikes the rotating blades which are fitted on a disc mounted on
a shaft. This high-velocity steam produces dynamic pressure on the blades in which blades and
shaft both start to rotate in the same direction. Basically, in a steam turbine pressure energy of

29
steam extracts and then it converted into kinetic energy by allowing the steam to flow through the
nozzles. The conversion of kinetic energy does mechanical work to the rotor blades and the rotor
is connected to a steam turbine generator which acts as a mediator. Turbine generator collects
mechanical energy from the rotor and converts into electrical energy.

Alternator: The steam turbine is coupled to an alternator. The alternator converts mechanical
energy of turbine into electrical energy. The electrical output from the alternator is delivered to the
bus bars through transformer, circuit breakers and isolators. The type of turbine which is found
here is impulse turbine.

The capacity of this turbine is:-

Rated output: 8 MW

Rated speed: 7034 rpm

Operating pressure: 24bar

Operating temperature: 350degree Celsius

3.5 Technical tasks/products

We were inexperienced professionals regarding the practical knowledge that can be grasped in the
company. Even the task we have been participating in was not completely successful because of
shortage of practical knowledge. So, we are forced to ask somebody who has good knowledge
about it. Particularly, the help of company workers could make our internship duration successful.

In spite of the fact, we have participated with the professionals to do the task. For instance, we
support machine operator and technician when they do different tasks, like operating machine, in
maintenance, and etc. Of course, it is somehow difficult to talk confidently the task we have been
executed independently.

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3.6 knowledge and acquaintances acquired

The knowledge acquaintances we have gained during our internship program are:

 Inter connecters of material from different fields of study.

 In ability to see all of the apparatus, because, of their coverage since they may be case of
dangerous when exposed to outside.
 Ability to function on multidisciplinary teams.
 Understanding of professional and ethical responsibility.
 Ability to communicate effectively.
 Recognition of the need for and ability to engage in lifelong learning.
 Ability to use the techniques, skills, and modern engineering tools.
 Electrical maintenance practice.
 Electrical motor rewinding.
 How sugar can be produced.
 How speed of induction motor can be controlled.
 How to regulate temperature.

3.6.1 Technical Skill Gained

During we have stayed in ADSF we spent most of the time with electrical and mechanical
technician by observing practical skills, working procedures, proper use of the materials and
identifying the right material for the right purpose especially when changeover and machine
breakdown happened and also when the 5S technique applied for every machine. To improve this
practical skill, we

 Exchange information with technician and operator.

 Asking the question and understand the working principle.

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3.6.2 Management Skills Gained

As we have seen during the internship duration we have learnt that the way how the manager leads
the respective teams, for men leads its co-workers and the like at work place. Generally we have
noticed the following important points from the management skill:

 Ability to encourage and motivate workers to do their best.

 The ability to communicate with all workers without any force.
 The ability to listen problems and focus on its solution.
 As leader to have clear and defined goals missions and vision.
 Also learns some solve any problems developed.

3.6.3 Acquaintances Acquired

We used to acquire great benefits from this internship in the following aspects:

 Improve our practical skills.

 Upgrade our theoretical knowledge.
 Improve our interpersonal communication skills.
 Improve our leader ship skills.
 Know work ethics related issue.
 Team playing skills.
 Know about entrepreneurship skills…etc.

3.7 Contribution

The contribution of the internship program is not only for practical but it also upgrades our
theoretical knowledge. It increases the ability to apply systematic design procedure. Internship
memorizes the important conceptual theoretical parts that we have learned.

During this internship program we develop the following toward internship.

 Self confidence
 Willingness to take risks
 Creativity
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 Yes, I can do
 Understanding the wiring diagram of the machine

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 CHAPTER FOUR

4. GENERAL COMMENTS AND CONCLUSION

In our duration of internship in ADSF some things we mentioned is important for improvement.
By studying the company organization structure and work flow, we would like to comment this
company with the following terms:

 We need to comment that the bagasse which leaves the mill is wet and it affects boiler
efficiency, so the bagasse must be dried using bagasse drier before it enters to furnace
to increase efficiency of boiler.
 Additionally, we would like to give comment that the harvested cane stays for a long
period of time in a field before it is feed to crusher, this causes loss of sucrose content.
So that to minimize the loss we must feed the cane to the crusher as soon as it comes
from the cane field.
 Ethanol is produced from final molasses. In this factory there is no a machine which is
used for ethanol preparation. So, we would like to comment that a machine should be
constructed.
 Bagasse is not well protected from rain and its high moisture affects boiler. So, the
bagasse outlet should be have storage house.
 Finally, there is no needed utility (house, transportation, library, computers and
laboratory) for internship students. So the company should be provide those materials.

4.1 Problem encountered during the internship period

“Life is a challenge, but challenges can always be overcome”

One of the main expectations as we an intern is to do some work or some practical works related
with our field but we don’t get that much work rather we are confused and simply waste the time.
Secondly, we don’t get enough guidelines or directions from the factory’s supervisor.
Unavailability of access of an internet and the environmental condition influence were major our
problem encountered.

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To fulfill the factory aim and method within the required time limit some general limitations have.

Those limitation and restriction are:

 Scarcity of the machine which used for cane loaded.

 Sometime electrical system cannot work properly due to insufficient of bagasse in the
boiler.
 Sometime the Quality of sugar cane is low then the output sugar is low and the filter cake
high.
 Insufficient of dam construction.
 All machines are not automatic, some machines are manually operated.
 Motor failure was appeared frequently especially induction motor
 Decrement and increment of the load that is not operate as its required

4.2 General Suggestions and Comments to the Company

To avoid the scarcity of machine in the company, workers must talk with all leaders in this
company and study deeply which machine is great role in the company.

 To eliminate the insufficient of bagasse workers can substitute by preparing the coal from
the wood or buy the coal from market simply.
 To keep the quality of cane, dam construction must be fulfilled in the short period of time.
Because if the cane is not developed with sufficient water, the extracted juice from this
cane is small and the garbage is maximum. Also the filter cake is high and the output sugar
is very small.
 If all machine is automatic simply they can identify when the problem is occur ,but in case
of manually operated machine difficulty to know the damaged part takes many times to
repair. Therefore, if it changes in to automatic its best.
 Power source should be balance with the load.

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4.3 Summary and Conclusion

This internship helps us a lot in gaining the necessary practical application that we can use for the
future. And also it helps us to assure that the field we studying is the right career with a big
responsibility. As it is known, the objective of the internship is to acquire good working skills and
knowledge, and provide the student an opportunity to integrate theory and practice to his/her
professional education, by encouraging the exchange of insights between the professional agency
and the student. On our part we have tried to make use of this chance. So, in duration of our
internship we stayed in ADSF, we understood many knowledge and we also gained many skills
from factory.

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 CHAPTER FIVE

5. PLC BASED AUTOMATIC TEMPERATURE AND WATER LEVEL

CONTROL SYSTEM FOR BOILER PROTECTION

5.1 INTRODUCTION

Industrial boiler is the foremost part in any power plant and a system designed to produce steam
in varying quantities for a variety of applications including space heating, process heating, power
generation and other huge industries. In Power plants it has number of boiling section and this
boiling section produces the high temperature water of the steam. Boiler steam temperature in
thermal power plant is very complex and hard to control, due to poor knowledge of the working
principles. Boilers have many serious injuries and destruction of property. It is critical for the safe
operation of the boiler and the steam turbine. If the level is too low, it may overheat boiler tubes
and damage them. If too high, a level may interfere with separating moisture from steam and
transfers moisture into the turbine, which reduces the boiler efficiency.
In order to automate a power plant and minimize human intervention, there is a need to develop a
Boiler Automation system. It is achieved by using Programmable logic controller that helps to
reduce the errors caused by humans during manual working and avoids the catastrophic failure.
Boiler temperature and water level using different sensors and the corresponding output is given
to the PLC which controls the boiler temperature, pressure and water level. Water plays a major
part in the generation of steam. Feed water pump and heaters are switched ON by using PLC. The
PLC receives input from different sensors to fully open and close the water pump and the heaters.
This project is specified for temperature and level control using ON-OFF controller.

5.2 Statement of problem

Controlling boiler system is very critical issues in modern process control application. Over a year
the industrial boiler is controlled using manual ON and OFF system. Controlling boiler using
manual control strategies provides engineering operators life and poor performances, resulting in
low quality process output, and reduce profits of process industry. Therefore, in this project, we
have designed PLC based automated electric boiler control system to solve the problem related

37
manual control system. For this analysis Logo PLC software is used, and the system can control
temperature and water level boiler control parameters according to the design algorithms.

5.3 Objective

5.3.1 General objective

The main objective of this project is to design and simulate of PLC based industrial boiler
automation system and protection using Logo PLC software.
5.3.2 Specific objective

This project aims to achieve the following specific objectives:

 Comprehensive the study about electric boiler system
 To design electric boiler control system using programmable logic controller
 To simulate the control system parameter such as temperature and level using Siemens
Logo PLC software environment.
 Analyses the performance of the system

5.4 methodology

A development method may be regarded as a path or a procedure by which the developer proceeds
from a problem of a certain class to a solution of a certain class.

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 Figure 14: methodology of the project

5.4.1 Block diagram

The block diagram of boiler automation consist the several parts as follow: PLC (programmable
Logic control), resistance temperature detector (RTD), level sensor, water pump and heaters. The
block diagram of the system is as figure below.
R

Relay Motor
Level Sensor
Pump

Power
PLC
Supply Relay Heater 1

Temperature
Sensor
Relay Heater 2

Figure 15: overall Block diagram of the system

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5.4.1.1 Block diagram description

Programmable logic controller (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. The PLC is composed of two basic sections, the Central Processing Unit (CPU) and
the Input/output (I/O) interface system. The PLC measures input signals coming from a machine
and through the internal program provides output or control back to the machine.
Level sensor
Level sensor are used to sense the level of water in the tank. The type of sensor used to sense liquid
material is capacitance proximity sensor and the sensor works on the detection of the change in
capacitance induced a surface that is brought near the sensing element.
Temperature sensor
This type of sensor is used to sense the temperature value of the industrial boiler automation by
compare and contrast the set point with the measured value of the system.
Water pump
Water pump is used to feed water to the boiler shell it is one of the most important component, it
starts automatically whenever there is water at the threshold level and this will keep the boiler’s
water level always above the threshold level.
Relay
The relay is an electrically operated device which is used to control a high voltage load circuit with
a low voltage control circuit and used to transform control signal into control action.
Electrical heater
An electric heating equipment has a high speed of response, lending it to rapid-cycling mass-
production equipment.it uses electrodes as the heat source and it is processed when electric current
passed through metal resistance-heating element that immersed in water.
5.4.2 System flow chart

The flow chart is used to describe the system in simple way and in an understandable manner. Also
it can be describing the all system such as: The system working principle, Sequence of operation,
Component working principle and others.

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Working principles of level sensor
After the system is energized, the level sensor starts sensing the level of water in the boiler and
sends the status of the water to the programmable logic controller (PLC). Then the PLC sends the
command to the outputs to control the level of water according to the programmers’ command. If
the water in the boiler becomes low, the low level sensor is energized and sends the information
to PLC. Then the PLC sends the command to the motor to start pumping. Also if the high level
sensor is energized, it sends the command to the motor to stop pumping.
Working principle of temperature sensor
After the system is energized the temperature sensor starts reading the status of the water
temperature and sends the information to the programmable logic controller (PLC), and the PLC
gives the command for the outputs. If the sensor reads low temperature and sends the signal to
PLC, the PLC sends the command to the heater to start heating. And if the temperature becomes
higher, the sensor sends the signal to PLC. And then the PLC sends the signal to one of the heaters
to stop generating heat.

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 Figure 16: Overall flow chart of the system

5.4.2.1 Overall flow chart description

As per the flow diagram the pump should be made on when water level is getting low and the
pump should have made ON until water level is reached high level. If during turn ON of the system,
the high level sensor sense water, the pump does not start. The motor starts only if the low level
sensor is sense water, means water is reached low level. We used two electric heaters in our system
to control temperature that related to the water level, such that: at low level, when pump is starts
to pump water as it explains in level sensor, heater one is turn ON, then after a certain time, when

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water level is going to high level, the on-delay timer (T016) that is connected to heater two is
energized, as a result heater two is energized to maintain the required temperature. But, if the
temperature is high one of or two of them are turn OFF by comparing the water level. Also if water
level is high and temperature is low the both heater is turn ON. The system is continuing
automatically as the programmed by the work of programmable logic controller.
5.4.3 Assignment of input/output and ladder diagram development

Level sensor controller

We select the inputs and outputs for level sensor of the boiler and we put their assignment symbols
in the table below as shown.
Table 3: Input/output assignment of level sensor

NO. symbol Description (comment)

Inputs/out puts
1 I1 Low level sensor
2 I2 High level sensor
3 I3 Low temperature sensor
4 I4 High temperature sensor
5 Q1 Motor pump ON/OFF

Temperature sensor controller

We select the inputs and outputs of temperature sensor of the boiler and we put their assignment
symbols in the table below as shown.
Table 4: Input/output assignment of temperature sensor

No. symbol description

Inputs/out puts
1 I3 Low Temperature Sensor
2 I4 High Temperature Sensor
3 Q2 Heater 1
4 Q3 Heater 2
5 T016 Timer /ON Delay

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5.5 RESULTS

Simulation Results

Industrial boiler has different parameters which needs to be controlled, the water level and
temperature of the system are simulated and discussed in different condition of the parameters to
be considered in the boiler. In this Project, the following cases are specifically considered.
These cases are;
I. When level is low
II. When level is high
III. When level is high and temperature is low
IV. When both level and temperature are low
V. When level is low and temperature is high
Case I: When level is low
As shown in figure (a) and (b), when the water level is low the motor pump(Q1) starts pumping
the water and heater one (Q2) become energized as shown in figure (a) below. When the water
level reaches high level, the second heater (Q3) become energized in order to achieve the required
amount of heat as shown in figure (b).

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 (a)

(b)

Figure 17: When level is low (a) and (b)

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Case II: When level is high
When the water reaches high level, the motor pump stops pumping and both heaters are energized
to maintain the required heat as shown in figure below.

Figure 18: When level is high

Case III: When level is high and temperature is low

At this time level is high and temperature is low, both heaters are energized and the motor pump
stops pumping water as shown below.

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 Figure 19: When level is high and temperature is low

Case IV: When both level and temperature are low

When both level and temperature sensors reads low, motor pump starts pumping and heater 2 is
energized after certain time of pumping.

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 Figure 20: When both level and temperature are low

Case v: When level is low and temperature is high

When level is low and temperature is high, motor pump starts pumping, then heater 1 is turn ON
after motor pump is starts to pump the water.

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Figure 21: When level is low and temperature is high

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5.6 CONCLUSION AND RECOMENDATION

5.5.1 Conclusion

Industrial boilers encompass the category of boilers used in manufacturing, processing, mining,
and refining or any other industry to provide steam, hot water, and/or electricity. Industrial boiler
systems are used for heating with hot water or steam in industrial process applications. However,
the quality and efficiency of boiler is low as well as there is lack of continuity in the production
due to errors in measuring and taking control action involved with the operators or manual workers.
It is harm full to the operators while controlling the system manually. In case, if the system
equipment’s has been failed, the operator’s consequences to danger in life and the companies also
exposed to economic degradation. Further, lack automated control system results to low
productivity, wastage of energy and time, which interns reduce the profitability of the company.
Owing to this problem this thesis introduces industrial control automation like temperature and
level of the boiler using the Logo! Soft comfort software. Industrial automation using PLC is
introduced to reduce its overall expenditure in terms of wages, wastage of material due to
inaccurate manual work and to reduce the overall time taken for production.
Generally, this thesis solve the problem related to manual system, provide better control strategy
for boiler control system and increase the profit gained from industrial processes that used boiler
in their system.

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5.5.2 Recommendation

In this project automatic PLC based boiler temperature and water level controlling using ON-OFF
controller has been introduced. There are so many parameters that have to be controlled in
industrial boiler. But our project focuses on the two specific parameters only (temperature control
and level control) to control them automatically using PLC. But this may not be enough to control
the entire components of industrial boiler and to make that industries more profitable. Therefore,
to operate industrial boiler automatically and to control all component of industrial boiler our
future work is to control all the appliances and process of the boiler, using appropriate analog and
digital sensors, use larger volume of boiler to decrease repetition, controlling the pressure of the
boiler and etc. Additionally, in this system the water pump is controlled by ON OFF controller,
i.e. the pump is fully opened and fully closed. So we recommend that one have to use the advanced
controllers like PID controller, Model predictive controller and intelligent control in order to
control some other parameters.

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REFERENCES

[1] "WWW.Arjo didessa sugar factory google.com," [Online].

[2] operation manual of the factory.

[3] Jacek F. Geiras, electrical machine, 2017.

[4] Petruzella, F. D., programmable logic controller, McGra hill, 2005.

[5] o. m. o. t. factory.

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APPENDIX

Ladder diagram
Temperature sensor simulation ladder diagram

Level sensor simulation ladder diagram

Over all system of ladder diagram for industrial electric boiler automation

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