Industrial Training Report Format Updated Version338 1342 1
Industrial Training Report Format Updated Version338 1342 1
Industrial Training
At
Submitted by
Supervised By
An industrial training report submitted to the Department of EEE for the partial
fulfilment of the degree of B.Sc. in Electrical & Electronic Engineering
October, 2023
Certification
This is to certify that this industrial training report is done by the following student under
my direct supervision and this industrial training has been carried out in “Faman Tech
Corporation” of partial fulfillment of the requirements for the degree of Bachelor of
Science in Electrical and Electronic Engineering Department, Green University of
Bangladesh. The presentation of the industrial training was held on October, 2023.
————————
Md. Atiqur Rahman Udoy
ID: 201901034
———————— ————————
Professor, Department of EEE Application Engineer
Green University of Bangladesh Faman Tech Corporation
Dedication
And lastly, I dedicate this industrial book to the Almighty God who gives me strength,
wisdom, guidance, power of thinking, security, competence, and for giving me good
health while doing this. All of these, I offer to you.
Abstract
This industrial training in the field of Electrical Engineering at Faman Tech Corporation
focused on Control Systems and Automation also to bridge the gap between academic
concepts and real-world practices. The main objective of this training was to gain
practical knowledge and experience in designing, implementing, and solving real-world
problems from experienced professionals through hands-on exercise. During the
training, various aspects of the control system and PLC were covered, including system
architecture, equipment integration, and connection. Through workshops and practical
sessions, I acquired essential skills in configuring control systems and designing control
strategies. At first, I was introduced with the fascinating world of control systems where
I covered control system components fundamentals concepts. Then I worked on an
important project called the Control panel for ETP plant. where I became familiar with
essential tools and equipment needed for its implementation and learned to select the
correct cables and equipment by ensuring its performance and safety. Furthermore, I
gained some valuable experience in PLC wiring and completed the upper part of the
connection by taking help from experienced professionals. Then hand on exercises of
VFDs in assembly and wiring helps me to understand the operation and significance of
VFDs in industries. Overall, this training helped me a lot to understand industrial control
systems, from basics to their practical implementation in real-world projects. As I have
participated in various work, I have learned some valuable skills that can be directly
useful in the industrial sector and this training not only improved my technical
knowledge but also made me more confident in control systems projects. Therefore, this
hands-on experience, guided mentorship, and real-world projects will definitely guide
my career in the control systems industry.
i
Acknowledgment
First of all, I would like to thank Almighty for his mercy and charity. Without the grace
of Almighty, it would not be possible to complete the Industrial training.
We would like to express our sincere gratitude to our honorable co-supervisor, Md.
Tariqul Islam Lecturer, Department of EEE, GUB, for his guidance, support, enormous
care, motivation, and encouragement throughout the period of this training was carried
out. His readiness for helping us at all times, his willingness and positive attitude to
share thoughts, and his educative comments and assistance have been invaluable. We
will ever be grateful for his hearty cooperation and amiable demeanor.
Finally, we would like to thank our parents for always supporting us. We would also like
to thank our supervisors and fellow learners for being so supportive.
Sincerely,
ii
Contents
Abstract …………………………………………………………………………… i
Acknowledgment …………………………………………………………………. ii
List of Figures……………………………………………………………………... iv
List of Tables……………………………………………………………………… v
List of Symbols……………………………………………………………………. vi
List of Acronyms…………………………………………………………………... vii
Chapter 1 Introduction………………………………………………………….. 8
1.1 Literature Review…………………………………………………………… 8
1.2 Industrial Control System…………………………………………………… 8
1.3 Industrial Training Topic……………………………………………………. 9
Chapter 2 Company Profile……………………………………………………... 10
2.1 Brief Overview of The Organization…………………………………........... 10
2.2 The Role of The People……………………………………………………... 12
2.3 Justification of this Industrial Training Work………………………………. 13
Chapter 3 Activities, Experiences, Analysis, and Discussion…………………. 14
3.1 Training Activities…………………………………………………………... 14
3.2 Introduction to Industrial Control System…………………………………. 15
3.3 Components of Industrial Control Systems………………………………….. 15
3.4 Overview of Various Projects and Their Prior Preparation………………….. 16
3.5 Familiarization with Components used in Control System Projects………… 17
3.6 Fundamentals and Connection Practice of DOL and Star Delta Starter…….. 20
3.7 Started Control Panel for ETP plant Project……………………………… 21
3.8 Started control panel project for ETP plant…………………………………… 26
3.9 Training Experience………………………………………………………….. 27
3.1 Discussion……………………………………………………………………. 29
0
Chapter 4 Conclusion and Recommendation…………………………………... 30
4.1 Overview………………………………………………………………………… 30
4.2. Problems…………………………………………………………………………. 31
4.3 Internship Influences Career 32
Plan…………………………………………………
iii
iv
List of Figures
v
List of Tables
vi
List of Acronyms
PLC Programmable logic controller
ICS Industrial control system
HMI Human Machine Interface
SCADA Supervisory Control and Data Acquisition
ETP Effluent Treatment Plant
DOL Direct On-Line
P&ID Piping and instrumentation
GA General arrangement
vii
viii
Chapter 1
Introduction
Ultimately, the actuators are directed by the controllers to carry out specific actions,
thereby modifying the process variables in order to uphold the desired conditions and
enhance productivity. Industrial Control Systems (ICS) play a crucial role in the realm of
industrial automation as they facilitate the acquisition and transmission of real-time data,
enable remote access and control, and contribute to the optimization of operational
Chapter 1: Introduction
The primary aim of incorporating industrial training courses into our curriculum is to
establish a connection between our academic education and practical experience in the
industrial sector. This integration facilitates hands-on learning opportunities and
enhances the transition from theoretical knowledge to real-world application.
Page | 10
Chapter 2
Company Profile
FAMAN VALUES:
Believes in ethical and transparent business practices.
Customer satisfaction is Faman's foremost priority.
Has to have a Human face for its customers, its vendors, staff, & the society at
large.
FAMAN VISION:
MAIN ACTIVITIES:
FAMAN MISSION:
Page | 12
Chapter 2: Literature Review
CEO
At Faman Tech Corporation
Anom Kumar
Md.Mamun Islam Tanvin Sifat
Senior Biomedical
Automation Engineer Biomedical Engineer
Engineer
Page | 13
Chapter 2: Literature Review
Page | 14
Chapter 3
Activities, Experiences, Analysis and
Discussion
16/09/23 Started control panel project for Meghna Paper Plant (Taken
measurements & cut panel plates)
PLCs
Page | 16
Chapter 3: Activities, Experiences, Analysis and Discussion
Single Line Diagram: This type of diagram also known as a one-line diagram is a
simplified representation of the electrical system. This diagram uses standardized
symbols to represent various electrical elements and their connections.
Page | 17
Chapter 3: Activities, Experiences, Analysis and Discussion
Circuit breakers
VFD
PLC
Magnetic contactor
Circuit Breakers: Different types of circuit breakers are used in control systems, among
which we have seen MCCB, MPCB, and MCB. And in the control system, MCCB is
mainly used to protect the control panel. Because it can be used up to 2500-amp current.
On the other hand, we use MCB to protect low power load which can take up to 100-amp
current. By using MPCB breakers we can manually turn on or turn off the motor again it
can save the motor from various faults and it is mainly used to provide motor protection.
Page | 18
Chapter 3: Activities, Experiences, Analysis and Discussion
VFD: A VFD is a type of motor controller that controls the speed of the motor by
changing the frequency of the power supply. It has the ability to ramp up or ramp down
when the motor starts or stops. A typical VFD has three main parts, one of which is the
power conversion section, the microprocessor control section (CPU), and the power
section where the AC voltage is converted to DC and then the DC voltage is inverted
back to 3-phase AC voltage.
Page | 19
Chapter 3: Activities, Experiences, Analysis and Discussion
Page | 20
Chapter 3: Activities, Experiences, Analysis and Discussion
This type of starter is directly connected to the supply line and generally used for
motors in the 5 HP range. A typical DOL starter connection consists of 2 buttons,
including a starting button and a motor stop button, plus a circuit breaker, contactor, and
overload relay. To start the motor first, we need to press the start button which will cause
the current to flow through the contactor coil and the control circuit. This current
energizes the contactor coil and closes the contact causing the motor to run. Again,
when we press the stop button the contact will be disconnected and hence no supply to
the motor.
Advantages:
Star delta stator is used for higher-power induction motors. And in this method, the
motor is initially in star connection and when the motor reaches 80% of its full load it
starts running in delta connection. This connection requires a circuit breaker, contactor,
timer, push button. This method has very low starting torque, so this method is best used
when the starting load of an application is light.
Page | 21
Chapter 3: Activities, Experiences, Analysis and Discussion
Advantages:
Less mechanical stress & give high torque per ampere of line
On this day we have seen some tools & materials that will be used in the control panel of
ETP plant project:
Lug titter
U lug
I lug
O lug
Connector
Rivet gun
Supporter
Wire steeper
Insulator
Cable Lugs
Conduit
Page | 22
Chapter 3: Activities, Experiences, Analysis and Discussion
We saw the GA drawing of our project, and using this we have cut the panel plate and
made measurements. Where we have left space for the indicator, HMI, and alarm, in the
Front & upper of the panel so that they can be placed. Also, we have left space around
the panel to take the connection wire. We will always try to place the controlling devices
at the top of the control panel section and try to place the input supply section of the
panel at the bottom.
Page | 23
Chapter 3: Activities, Experiences, Analysis and Discussion
Fig 3.11: Front & side view of the control panel For ETP Plant
We need 1 DOL starter setup and 3 VFD setups for this project. Among them, 4
separate Circuit bakers are required for these 4 setups to protect them. And used 12
relays and 3 Fuse to control these three VFD setups using PLC. And we used a 12-bolt
and 24-bolt DC source to power the DC components of our project. And using
connectors to connect the rest of the components or Loads. Moreover, we have used
indicators to understand whether the load is on or off or whether any load has tripped.
And used small fans to keep the entire panel cool.
We have selected the wire through our load current calculation. The formula for load
current calculation is:
After calculating the load current using this table we have selected the wires
Wire Current
10RM 65A
4RM 32A
2.5RM 25A
Now that we've selected our equipment, and those components are
Source 12V DC
Source 24V DC
Power switch socket
Page | 24
Chapter 3: Activities, Experiences, Analysis and Discussion
we've set up the components as per our project's GA drawing. Also, we have placed the
bus bar of our panel on the insulator.
Here we take 24-volt DC from PLC and it will never depend on load. Then I connected
all the relays with 0-volt connection.
Page | 25
Chapter 3: Activities, Experiences, Analysis and Discussion
We have tried to control the motor speed of the system by placing the VFD on the panel
board made as per the drawing and wiring it properly. VFDs manipulate the frequency of
their output by rectifying an incoming AC current into DC, and then using voltage pulse-
width modulation to recreate an AC current and voltage output waveform.
We have done the panel board marking and wire pointing and leveling work beautifully
using the ferrule printing system. Ferrule printing refers to the process of marking or
Page | 26
Chapter 3: Activities, Experiences, Analysis and Discussion
labeling ferrules, which are small tubes or sleeves used to hold and protect the ends of
fiber optic cables. The printing on the ferrule typically includes information.
After making the main connection and body of the ETP plant project, we try to correct
the error & loose connection.
Fig 3.16: Final Connection Check of Control Panel For ETP Plant
Page | 27
Chapter 3: Activities, Experiences, Analysis and Discussion
General drawing, sizing, panel plate cutting and fitting, and wiring works for new project
ETP. So that it is convenient to work on the next step.
Fig 3.17: Cutting & sizing panel plates Meghna paper mill
project
All types of modules, devices, materials, panel boards – installation, and internal
connections are done as per drawings.
Page | 28
Chapter 3: Activities, Experiences, Analysis and Discussion
equipment. In our industrial training, we learned how to safely start a powerful motor
and control the same automatically using PLC. Because through the PLC, machines can
have controlled smoothly and quickly where manually it is impossible and difficult. We
have covered the topics in our power system protection class, such as DOL Starter &
Star-Delta connection for a motor, circuit breaker uses, magnetic contact, relay, etc.
Learned more with their practical application in our industrial training. Since we work
practically, we enjoy it and now we are used to doing all these things.
Page | 29
Chapter 3: Activities, Experiences, Analysis and Discussion
Fig 3.19: Control panel for both ETP & paper mill
3.10 Discussion
It is industrial training at the Faman Tech Corporation. Faman Tech Corporation
mainly deals in Automation, Control Panels, Power Panel, Liquid Processes, and
Erection. We basically got the opportunity to work directly on two projects of this
corporation. The first one is the control panel project for ETP. Where we worked on Star
Delta, DOL Starter, Frequency Control, and PLC. While working on the projects we
have come to know many control system equipment. We used VFD to control the speed
of the motor. Besides, we have been taught how to study the drawing of a project before
working on the hardware of a project. We have learned about GA drawing. We have
done the wiring as per the drawing. There was a lot of control equipment that operated
on DC and controlled AC lines such as Relay PLC. In the ETP plant project, we have
worked with 1 DOL starter and 3 VFDs. There was also a small setting of PLC. In ETP
Project we have worked with a lot of equipment. There was an entire panel of PLC And
there were 9 VFDs. Also, this project was star delta and dol starter. By training here we
were able to gain practical experience of the control system. I have learned many
practical things which are very different from the theoretical ones.
Page | 30
Chapter 4
During my industrial training to learn how to make circuit panel boards, I anticipate
encountering various challenges that might push me outside my comfort zone.
Adapting to New Technologies: As I embark on this training, I am well aware that the
field of electronics is constantly evolving, and I may come across new technologies. To
adapt to these changes, I plan to stay updated with the latest trends and continuously
learn about emerging technologies to broaden my skillset.
Dealing with failure: I understand that encountering failures or mistakes is part of the
learning process. Instead of being discouraged by them, I will embrace these experiences
Chapter 4: Conclusion and Recommendation
as opportunities to learn and improve my skills. I will analyze the reasons behind any
failures and proactively seek solutions to prevent similar issues in the future. In
conclusion, I am excited about this industrial training and the learning opportunities it
will offer. By approaching the challenges with a positive and determined mindset,
seeking guidance when needed, and dedicating time to practice and learn, I believe I can
overcome these obstacles and develop a strong foundation in making circuit panel
boards. I recognize that learning any new skill takes time and patience, and I am
committed to persevering and seeking improvement throughout this journey.
4.2 Problems:
In some cases, the drawing from which the work was started was slightly different
from the drawing, and at the end a final drawing was made.
The panel casing does not adjust properly if the material is slightly too low.
Due to lack of space, everyone was not working together on the same project.
The workshop temperature is much higher than the local area.
As the programming section of PLC is separate, we could not get the idea of
programming.
We could not learn E-CAD as the drawing section was separate
Page | 32