HAWASSA UNIVERSITY

INSTITUTE OF TECHNOLOGY
FACULTY OF MANUFACTURING
ELECTROMECHANICAL ENGINEERING

HOSTING COMPANY - ZERO LIQUID DISCHARGE (ZLD) PLANT,

HAWASSA INDUSTRIAL PARK

FINAL INTERNSHIP REPORT

Prepared By: ID NO
1. Dawit Demlie 0616/12
2. Meklit Asresahegn 0653/11

Duration of Internship Stay: MARCH, 11, 2015 EC-JUNE, 30, 2015 GC

ADVISOR: MRS. SENAIT A.

COMPANY ADVISOR: MR. MOHAMMED

Submission Date Oct, 4, 2015 GC

HAWASSA UNIVERSITY FINAL INTERNSHIP REPORT

DECLARATION

We are students of Electromechanical Engineering at Hawassa University who have completed our
internship training at IPDC/ZLD water Treatment Company for the past three months. We have
completed the internship program with a great performance and ethics. We announce and certify
that our work is original according to the guidelines for writing an internship report given by the
university.

Name of student Date Signature

1. Dawit Demile

2. Meklit Asresahegn

We declared that this final internship report and project were done by the above candidates, and they
have been submitted with our approval.

Advisor Date Signature

Mrs Senat A. (Msc)

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ACKNOWLEDGEMENT

At the very beginning, we would like to express our sincere gratitude to the almighty God for giving
us the strength to perform our responsibilities as an intern and complete the report within the given
time.
We would like to express our deepest gratitude to our company advisor and HR of the company, Mr.
Mohammed and Mr. Tigestu for their guidance, support, and encouragement throughout our
internship program, as well as all IPDC/ZLD employees who assisted us directly or indirectly with
our practical training and the preparation of this report. Their expertise and insights were invaluable
in helping us to develop our practical knowledge
Finally, we would like to thank our university advisor Mrs. Senait. A for her help and feedback. We
are grateful for her willingness to share her knowledge and expertise with us.

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EXCUTIVE SUMMARY

Internship program is arranged for students that completed their four-year courses according to the
stated program of Ethiopian ministry of Education. As we are Electromechanical students, we were
the part of internship for the last three months. The aim of this internship is to make students more
familiar with the work world, to make understanding and improvement of practical skill by relating
with their theoretical knowledge. It helps us in many ways and makes us familiar with work place
and carriers in the company as well as we get many tips how to behave in work place and how to be
entrepreneur in work area too. During our practical time, we have tried to improve our daily
activities, through time we have got confidence to participate in every activity. Here in the report,
we have explained and describe about our internship starting from introducing the company which
is known as ZLD. IT is among one of the companies that are found in the Hawassa Industrial Park
(IPDC). It is concerned with water treatment and reuse of it. The Company receives used toxic
water from the neighboring companies like textile, garment factories and accumulated toilet wastes
and purify it and send it back to them. Thus, it plays a great role in preventing environmental
pollution which is a major issue in our today’s world. In the process of water recycling many
machineries and auxiliary instruments are used with predetermined manufacturing process under
some standards. In our report we have described all activities and details of the companies working
and the experience that we have gained.

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Table of content

Content
pages

Declaration.................................................................................................................................

Acknowledgement....................................................................................................................

Excutive summary....................................................................................................................

List of figures.........................................................................................................................

List of abbreviations and acronyms..........................................................................................

Chapter one.................................................................................................................................

Introduction.................................................................................................................................
1.1 History of IPDC/ZLD Water Treatment Company...........................................................................

1.2 Mission.............................................................................................................................................

1.3 Vision................................................................................................................................................

1.4 Value and principles..........................................................................................................................

1.5 Mandates...........................................................................................................................................

Chapter two.................................................................................................................................

Overall internship experience.....................................................................................................

2.1 How we get in to the plant................................................................................................................

2.2 The process that takes place in the company....................................................................................

2.2.1 Effluent treatment plant (ETP)...................................................................................................
2.2.2 Ultra filtration and reverse osmosis (UFRO)...........................................................................
2.2.3 Polymeric film multi effect distillation (PFMED)...................................................................

2.2.4 Multi effect evaporation (MEE)..................................................................................................

2.2.5 Sewage treatment plant (STP).................................................................................................
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2.3 Sections of the company we have been workingon........................................................................

2.3.1 Electrical department...............................................................................................................
2.3.2Steam Generation Section.........................................................................................................
2.3.2 Instrumentation department.....................................................................................................
2.3.3 Mechanical department............................................................................................................
2.3.3 Valve.........................................................................................................................................
2.3.4 Industrial automation...............................................................................................................
2.3.5 What Procedure we Have Been Using While Performing Our Tasks......................................
2.3.6 What Kind Of Technical Challenges We Have Faced.............................................................
2.3.7 How Good we Have Been Performing....................................................................................
2.3.8 Measures We Have Taken In Order To Overcame the Challenges..........................................

Chapter three.............................................................................................................................

Overall benefits and challange of internship.............................................................................

3.1 overall benefits of Internship..........................................................................................................
3.1.1 In Terms Of Improving Practical Skill.....................................................................................
3.1.2 Upgrading Our Theoretical Knowledge...................................................................................
3.1.3 Improving Interpersonal Communication Skill.......................................................................
3.1.4 In Improving Our Team Playing Skill......................................................................................
3.1.5 In Terms Of Improving Our Leadership Skill..........................................................................
3.1.6 In Terms Of Understanding about Work Ethics and Related Issues........................................
3.1.7 In Developing Our Entrepreneurship Skill..............................................................................

3.2 Challenges We Have Been Facing While Performing Our Tasks...................................................

3.2.1 Counter Measures for the Challenges......................................................................................

Chapter four..............................................................................................................................

Design of electrical scissor lift..................................................................................................

Abstract.................................................................................................................................................
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4.1 Statement of the problem................................................................................................................

4.2 Objectives of the Project.................................................................................................................

4.2.1 General Objective....................................................................................................................
4.2.2 Specific Objective....................................................................................................................

4.4 Significance of the Project..............................................................................................................

4.5 Scope and Limitation of the Project..............................................................................................

4.5.1 Scope........................................................................................................................................
4.5.2 Limitations...............................................................................................................................

4.6 Literature Review...........................................................................................................................

4.6.1 Scaffolds...................................................................................................................................
4.6.2 Boom Lift.................................................................................................................................
4.6.3 Mechanical Scissor Lift...........................................................................................................
4.6.4 Hydraulic Scissor Lift..............................................................................................................
4.6.5 Electric Scissor Lift..................................................................................................................

4.7 Methodology...................................................................................................................................
4.7.1 System components.................................................................................................................

Chapter five...............................................................................................................................

Material selection and design analysis for the proposed work.................................................

5.1Material selection and Properties.....................................................................................................

5.2 Analysis of mechanical property requirement of essential machine components..........................

5.3 Choice of stainless steel and mild steel..........................................................................................

Geometric analysis....................................................................................................................
The maximum arm/linkage angle (𝛉max)............................................................................................

Chapter six................................................................................................................................

Proposed 3d model and 2d drawing of the components...........................................................

6.1 Proposed Prototype.........................................................................................................................
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6.2 Design of Components...................................................................................................................

6.4 Drafting and 3D Model...................................................................................................................

6.4.1 Isometric View.........................................................................................................................
6.4.2 Front View................................................................................................................................
6.4.3 Side View.................................................................................................................................
6.4.4 Assembly Drawing...................................................................................................................

Chapter seven..........................................................................................................................

Conclusion and recommendation............................................................................................

7.1 Limitation.....................................................................................................................................
7.1.1 Limitations of the University.................................................................................................
7.1.2 Limitations of ZLD plant.......................................................................................................
7.2.1 Recommendation for the University......................................................................................
7.2.2 Recommendation to the Company.........................................................................................

Reference................................................................................................................................

Appendix.................................................................................................................................

List of Figures
Figure 1.1: Top view of ZLD Company...............................................................................................................
Figure 1.2: ZLD Treatment System.....................................................................................................................
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Figure 2.1: ETP Receiving tank...........................................................................................................................

Figure 2.2: Receiving Pump.................................................................................................................................
Figure 2.3: Screen Chamber.................................................................................................................................
Figure 2.4: Equalization Air blower.....................................................................................................................
Figure 2.5: ETP process Flow............................................................................................................................
Figure 2.6: DMF Tanks......................................................................................................................................
Figure2.7: Basket filter.......................................................................................................................................
Figure 2.8: Ultra Filtration.................................................................................................................................
Figure2.9: SCADAs representation of PFMED.................................................................................................
Figure2.10: PFMED Feed Balance Tank...........................................................................................................
Figure2.11: Heat Exchanger...............................................................................................................................
Figure2.12: Vacuum Pump.................................................................................................................................
Figure 2.13: MEE-PHE-PRE HEATER.............................................................................................................
figure 2.14 Flash vessel......................................................................................................................................
Figure: 2.15 STP screening chamber.................................................................................................................
Figure:2.16 MCC ROOM..................................................................................................................................
Figure 2.17 PCC ROOM....................................................................................................................................
Figure2.18: Direct online starter method...........................................................................................................
Figure2.19: Star Delta starter method................................................................................................................
Figure2.20: VFD................................................................................................................................................
Figure2.21: star connection of motor.................................................................................................................
Figure2.20: Star Delta starter method................................................................................................................
Figure2.22: Miniature Circuit Breaker...............................................................................................................
Figure2.23Moulded Case Circuit Breaker.........................................................................................................
Figure2.24: Motor Protection Circuit Breaker...................................................................................................
Figure2.25: Air Circuit breaker..........................................................................................................................
Figure2.26: Contactor........................................................................................................................................
Figure2.27: Overload Relay...............................................................................................................................
Figure2.28: electric boiler..................................................................................................................................
Figure2.29: BOILER HMI and BOILER HEATER BANKS with Control Panel.............................................
Figure2.30 magnetic flow mete..........................................................................................................................
Figure2.31flow meter.........................................................................................................................................
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Figure2.31 ultrasonic level transmitter...............................................................................................................

Figure 2.32 magnetic type level transmitter.......................................................................................................
Figure 2.33 float operated mini level switch......................................................................................................
2.34 Magnetic type level switch.........................................................................................................................
Figure 2.35 magnetic type level switch..............................................................................................................
figure 2.36 float and board type level gauge......................................................................................................
Figure 2.37 piezoelectric type pressure transmitter...........................................................................................
Figure 2.38 pressure switch...............................................................................................................................
Figure 2.39 RTD.................................................................................................................................................
Figure 2.40 Temperature gauge..........................................................................................................................
Fig 4.1 Scaffolds................................................................................................................................................
Fig 4.2 Straight boom lift...................................................................................................................................
Fig 4.3 Articulated Boom Lift...........................................................................................................................
Fig 4.4 Mechanical Scissor Lift.........................................................................................................................
Fig:4.5 Hydraulic Scissor Lift............................................................................................................................
Fig: 4.6 Electric Scissor lift................................................................................................................................
Fig: 4.7 Scissor Link..........................................................................................................................................
Fig: 4.8 Ball Screw.............................................................................................................................................
Fig: 4.9 Ball nuts................................................................................................................................................
Fig:4.10: Bolt and Nut........................................................................................................................................
Fig 4.11: Push button..........................................................................................................................................
Fig: 4.12 Resistor...............................................................................................................................................
Fig: 4.13 DC Motor...........................................................................................................................................
Fig: 4.14 Arduino...............................................................................................................................................
Fig 5.1 :Geometry of the scissor lift in raised position......................................................................................
Fig.5.2. Geometry of the scissor lift in lowered position...................................................................................
Figure 6.1: Isometric View.................................................................................................................................
Figure 6.2: Front View.......................................................................................................................................
Figure 6.3: Side View.........................................................................................................................................

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LIST OF ABBREVIATIONS AND ACRONYMS

ZLD Zero Liquid Discharge

IPDC Industrial Park Development Corporation

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ETP Effluent Treatment Plant

UFRO Ultra Filtration and Reverse Osmosis
PFMED Polymeric Film Multi Effect Distillation
MEE Multi Effect Evaporator
STP Sewage Treatment Plant
DCS Distributed Control System
PLC Programmable Logic Controller
SCADA Supervisory Control And Data Acquisition

LIST OF TABLES PAGES

TABLE 1: CHEMICAL USED IN HARDNESS REMOVAL SYSTE-----------------------------16

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TABLE 2: CHECK LIST (SET POINTS): -------------------------------------------------------------16

TABLES 3: DETAIL OF COMPONENTS-------------------------------------------------------------87

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CHAPTER ONE

INTRODUCTION

1.1 History of IPDC/ZLD Water Treatment Company

The Hawassa Industrial Park is located in southern Ethiopia, and it was completed in July 2016 with
assistance from China. Sitting on1.378 million square meters. The park hosts 52 factories that boast
cutting edge infrastructure and equipment. Also, the park was designed with numerous energy
saving features. ZLD is among those companies which is playing a great role in water conservation
and protecting the environment from pollution. A ZLD system involves a range of advanced
wastewater treatment technologies to recycle, recovery and reuse of the ‘treated’ wastewater and
there by ensure there is no discharge of wastewater to the environment. In other words, Zero Liquid
Discharge (ZLD) is an ambitious wastewater management strategy that eliminates any liquid waste
leaving the plant or facility with the majority of water being recovered for reuse. Zero Liquid
Discharge (ZLD) obviates the risk of pollution associated with wastewater discharge and maximizes
water usage efficiency.
The ZLD Technology is highly recommended for industries generating a wastewater with high
TDS/ salinity such as pharmaceutical, pulp and paper, tanneries and textile plants. This is because
the inability of removing the salinity in a waste effluent by the conventional treatment methods i.e.,
physio - chemical and biological methods.
ZLD technology is beneficial for the plant’s water management; encouraging close monitoring of
water usage, avoiding wastage and promotes recycling by conventional.
Generally, there are three principal benefits of this type of facility. Firstly, it recycles greater than
95% of the water so as to reduce the natural water demand. Secondly, recovery of over 90% of salt
as bi-products. Finally, it’s contribution in the protection of the environment from wastewater
discharge pollution by meeting the stringent regulatory limits.

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The park is expected to generate 100,000 local jobs (from IPDC). The facility complies with a zero-
emission standard resulting in 90% of water being recycled. Rainwater collection and landscape
pools are in place to green the surrounding area, a strategy which reduces local water consumption.
Designed to reflect regional and cultural characteristics, the park also has 60,000 trees and 470,000
m2 of lawn. Vocational training was provided for all construction and technical employees over the
nine months period of active construction. Other project benefits include increased employment for
those living around Hawassa, stronger local labor skills and etc. Hawassa zero liquid discharge plant
is one of the company found in Hawassa Industrial Park to treat different source waste water
discharged from different factories or sheds. After treating waste water the plant will distribute the
treated water for different factories. ZLD–meaning zero discharge of waste water from Industries. A
ZLD system involves range of advanced waste water treatment technologies to reduce, recycle and
re-use of wastewater and there by ensure there is no discharge of wastewater to the environment. An
efficiently designed zero liquid discharge (ZLD) system is used for minimizing the significant of
wastewater requiring treatment and also to produce a stream of water suitable to be reuse by the
industries.

A general approach for ZLD is to increase concentration of wastewater and further crystallize to a
solid. Zero Liquid Discharge Treatment Plant (ZLD) that enables to recycle of 95 percent of the
industrial and domestic wastewater sewerage from all investors fulfils international standards. The
park will serve as a prototype for all the industrial parks being built in other parts of the country.
Zero Liquid Discharge has gained traction due to a growing, global concern about the impact of
wastewater discharge on the environment.

As it has been already mentioned above industrialization is necessary for country’s economic
growth. Increase in industrial development has elevated water consumption and is resulting in
depletion of water resources. On the other hand, water pollution is a major issue. It has long been
tried to find cost effective and reliable ways to treat wastewater and recycle or reusing the treated
water has become a necessity. In addition to this to save Lake Hawassa and the beautiful tourist
Hawassa city, Zero Liquid Discharge (ZLD) is an ideal situation of complete closed loop cycle,
where discharge of any liquid effluent is eliminated. This is a remarkable effort of IPDC to meet
with the environmental regulation in a challenging way. However, it is facing some challenges for
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its implementation including its high costs and energy efficiency. In any case, IPDC is moving
forward with the cooperation of the investors and all other concerned bodies. Envisol recycled
100% of the available

water consumed by the Hawassa Park, one of Africa’s largest industrial parks with the lowest cost of
operations in the world. The Lake Hawassa remains pristine, without any contamination and
deterioration of its water level Envisol’s Zero Liquid Discharge technology has helped us create
environmentally friendly water systems, protecting Lake Hawassa.

Thereby striking a balance between exploitation of fresh water resources and preservation of aquatic
environments. Achieving ZLD, however, is generally characterized by intensive use of energy and
high cost. There are physically big plants installed there and many processes are undertaken in order
to pure the water. So the power consumption is expected to be high. The overview highlight about
the company is described with a picture below.

Figure 1.1: Top view of ZLD Company

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1.2 Mission
IPDC is committed: -
 To boost industrial parks development through the highest standards of
professionalism
 To drive industrialization
 To promote exports
 To promote employment opportunities
IPDC sets the above missions; there by the country's development goal will achieve the
middle-income status.
1.3 Vision
Industrial Park Development Corporations (IPDC) vision is to be innovative and leading
Eco industrial parks developer and operator in Africa by 2025. And also, to create
more than two million jobs and grow the manufacturing industry to 25% of Ethiopia’s
economy.
1.4 Value and principles
IPDC/ZLD Company is established based on various values and principles. Some of them
are listed below: -
 Responsibility
 Transparency
 Team work or co-operation
 Active participation
 Readiness for change
 Highest level of integrity and professionalism
 Learning organization
 concern to the environment
 Effectiveness and efficiency customer satisfaction
1.5 Mandates

 Develop and administer Industrial Parks, lease developed land, lease and transfer,
through sale, construction thereon;

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 Prepared detailed national Industrial Park Master plan based on the national special
Master plan and serve as the Industrial Park land bank in accordance with the
agreements conclude with regional governments;
 In collaboration with the concerned bodies, ensure that the necessary infrastructure is
accessible to Industrial Park developer;
 Outsource, through management contracts when it is deemed necessary the
management of Industrial Parks;
 Promote extensively the benefits of industrial parks and thereby attract investors to
the Parks; In line with directives and policy guideline issued by the Ministry of
Finance and Economic Development, sell and b ledge bonds and negotiate and sign
the loan agreement with local and international financial source; and
 Engage other related activities necessaries of the attainment of its purpose;
 Since Hawassa Industrial Parks one of the Industrial locations under IPDC it
operates the above IPDCS mission, vision and values except the mandates.
The Zero Liquid Discharge system comprises of the following components.

 Pre-Treatment (ETP)
 Ultra Filtration & Reverse osmosis
 Evaporator and Crystallizer

Figure 1.2: ZLD Treatment System

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The main Process are listed below:

 Pre-Treatment (ETP)

 Hardness Removal System (HRS)

 Polymeric Film Multi Effect Distillation (PFMED)

 Multi Effect Evaporation (MEE)

 Centrifuge (Pusher type: Salt Recovery)

 Cooling Tower

 Boiler

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CHAPTER TWO

OVERALL INTERNSHIP EXPERIENCE

2.1 How we get in to the plant

After the successful completion of Fourth year study in technology field from Hawassa university
department of Electromechanical Engineering we get the chance to practice for the last three month
internship program in order to get the real world experience and what look like the practical thing
what we have learned since the last Fourth years and comparing with theoretical class.

2.2 The process that takes place in the company

Our internship plant i.e., Zero liquid discharge (ZLD) serves as the treatment area for the whole
wastewater that comes out of the factories inside the Hawassa industrial park into pure water that
satisfies all the requirements and a solidified sludge which can be used for greenery’s as compost.
The wastewater from the different factories transported through underground piping in to two
treatment plants. These are EFFLUENT Treatment Plant (ETP) and SEWAGE Treatment Plant
(STP). Sewage Treatment Plant (STP) treats all the sewages that come from the industries whereas

2.2.1 Effluent treatment plant (ETP)

This plant serves as a treatment for effluents that come from the industries. It has similar process
with sewage treatment plant but there are differences related to pH stability. It begins its process in
the Receiving Chamber where wastewater having different irregular in characteristics such as high
pH, organic/inorganic load are collected. It is the first stage where the company receives waste
products of the neighboring industries. Textile and garment factories send their waste water to the
receiving tank that is found on the ETP sector.

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Figure 2.1: ETP Receiving tank

From the receiving tank the water is pumped to grit screen chamber where large floating particles
and plastic bags are removed.

Figure 2.2: Receiving Pump

The function of the Coarse bar screen is to prevent entry of solid particles above a certain
size. After fine bar screen chamber Effluent comes to Grit Chamber through gravity. In
Grit Chamber, to remove grit, consisting of sand, gravel, cinder, or other heavy solids
materials that have specific gravity much higher than those of the organic solids in
wastewater and disposed off after washing to remove higher size organic matter settled
along with grit particles.

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Figure 2.3: Screen Chamber

In ETP sector the main processes are:

 Biological Treatment

 Chemical Treatment

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 Color Removal
The above processes are done on the equalization tanks where effluent of different intensity is
mixed for uniform blend with the help of air blower.

Figure 2.4: Equalization Air blower

The flow cycle of the water on the ETP section is listed on the picture below.

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Figure 2.5: ETP process Flow

The wastewater is fed in to three primary clarifiers using centrifugal feed pump. These
primary clarifiers are used to remove color while the suspended solids are removed by
coagulation and flocculation by adding chemicals. Next to the primary clarifiers the
floating wastewater is transported into aeration tank which is a biological process of
decomposing the effluent using microorganisms. Aerobic microorganisms are cultured in
the aeration tank using. In addition to air blower diffuser is used in aeration tank for better
contact of oxygen and food with microorganisms. The aerobic microorganisms biodegrade
the residual organic matter present in the clarified effluent. Separation of biological sludge
which is used as activated sludge takes place in the secondary clarifiers. In these clarifiers
the bacteria that feed in the organic matter and convert the dissolved organics into carbon
dioxide and additional bacteria are settled out by gravity. Sludges from primary and
secondary clarifiers undergo further processes such as sludge dewatering using centrifuge.
The centrifuge removes moisture from the sludge and inject using two ports. I have
observed that the company uses this sludge for greenery’s as compost for settling the
unsettled sludge the wastewater goes in to the tertiary clarifier. This clarifier helps to
remove any bacteria if after secondary clarifier. The clear water after sedimentation will
not be pure, and may contain very fine suspended particles and bacteria’s. Dual Media
Filter is provided in the system to remove suspended solids in the wastewater. It contains
sands of different grades for filtering the suspended particles. As I saw the clarified water
finally goes into treated water storage tank.
2.2.2 ULTRA FILTRATION AND REVERSE OSMOSIS (UFRO)
The next stage after ETP treatment is done on the plant named UFRO. The system consist of
following equipment’s for treating ETP discharge water
(1) Dual Media Filter
(2) Basket Filter
(3) Ultra Filtration
(4) Micron Cartridge Filtration
(5) RO
(6) CIP for UF+RO

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2.2.2.1 Dual Media Filter

Filtration of water for removal of suspended impurities is an integral step in the treatment scheme
for various applications. Filtration is also an important pretreatment step for ion exchange systems
(such as softener etc.,) and membrane systems (such as reverse osmosis desalination, etc.) for
protecting the ion-exchange resins and membranes from physical fouling due to suspended
impurities present in water & system effectiveness for such kind of Pre-treatment.

Figure 2.6: DMF Tanks

2.2.2.2 Basket Filter: -

Basket Filter consists of a SS316 vessel installed with a 150 micron SS Filter element. This helps to
reduce further suspended impurities to acceptable level and hence safe guard the Ultra filtration
Membranes. The Basket Filter shall be equipped with necessary pressure gauges for monitoring the
pressure drop across Filter.

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Figure2.7: Basket filter

2.2.2.3 Ultra Filtration
Ultra filtration removes particles in the range of approximately 0.1 to 1 micron. In general,
suspended particles and large colloids are rejected while macromolecules and dissolved solids
pass through the UF membrane. Applications include removal of bacteria, flocculated materials,
or TSS (total suspended solids). Transmembrane pressures are typically 0.7 bar (10 PSI).

Figure 2.8: Ultra Filtration

2.2.2.4 Micron Cartridge Filter: -

The Micron Cartridge Filter consists of a SS 316 vessel installed with a 5µ poly propylene
disposable cartridge. This helps to reduce the Silt Density Index to acceptable level and hence safe
guard the R.O. Membranes. The MCF shall be equipped with necessary pressure gauges for
monitoring the pressure drop across the cartridges.

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2.2.2.5 Reverse Osmosis; -

The osmotic process makes life itself possible. It is used to transfer nutrients into and waste
products out of every cell in the human body. Osmosis occurs when two water solutions of differing
concentrations of dissolved solids are separated by a semi permeable membrane. A semi
permeable membrane allows small molecules and ions to pass through it but acts as a
barrier to larger particles or dissolved substances. Water molecules can pass through the
membrane, but molecules or particles of substances dissolved in the water cannot. If two
different concentrations of solution are arranged on either side of a semi permeable
membrane as shown in the figure above right, the water molecules will migrate through the
semi permeable membrane and cause the level on the more concentrated side to rise. Even
though the solutions on both sides of the membrane are at the same pressure, water flows from
one side to the other, due to osmosis. The difference in water level between the two
solutions represents the force moving the water from one side of the membrane to the other. This
force is the osmotic pressure. The application of Reverse Osmosis to the solution of problems
in water treatment requires an understanding of the basic mechanisms involved in the
process, the Limitations of Reverse Osmosis and the pretreatment requirements.
Reverse osmosis is the process by which water is forced by pressure through a
semipermeable membrane. Water is passed through the membrane while the particulate & dissolved
matter is left behind. When pressure is applied to the concentrated solution, water is forced through
the membrane from the concentrated side to the dilute side.
Reverse Osmosis utilizes the unique properties of a semi-permeable membrane to allow fluid to
pass while restricting the flow of dissolved ionic material. When pressure is applied to impure water
on one side of such membrane material, pure water will pass through, leaving most of the impurities
behind. The rejection of the dissolved ionic material is a function of both molecular weight and
ionic charge. For example, we can expect a nominal 90% rejection of Sodium chloride, which
means that the product water passing through the membrane will have a concentration of salt
approximately one-tenth that of the feed water. The rejection of Calcium carbonate (hardness) will
be near 95%, while most metallic salts will be rejected at a rate of 98% to 99%.the rejection of non-
ionic or organic material is primarily by mechanical filtration i.e. Pretreatment of feed water prior to
Reverse Osmosis system.
The application of Reverse Osmosis to the solution of problems in water treatment requires
an understanding of the basic mechanisms involved in the process, the limitations of Reverse
Osmosis and the pretreatment requirements.

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The Reverse Osmosis system is composed of two major parts; the high pressure pump and
the membranes. The initial purified water production rate is measured at this pressure. It appears
that there are longer term benefits to be gained by operating at lower percent water recovery,
particularly in reducing maintenance to the systems, and minimizing precipitation problems which
may arise due to operator error. It is important to realize that the purified water from a Reverse
Osmosis system is delivered essentially at atmospheric pressure, usually to a vented storage tank.
In general, it cannot be operated by opening and closing a valve in the product water line
(unless special pressure relief is provided). The reason for this is that the high pressure in
the system drives the water across the membrane, and no flow of water would be possible if the
pressure on both sides of the membrane were the same. If, for some reason, the product water
line was closed while the system was operating, the pressure would build up .The plastic tubing on
the product water side normally would not tolerate high pressure.

The membranes are capable of taking forward pressure, i.e. from the direction of the supply
water side to the purified water side. However, they can not tolerate “back" pressure, i.e., in the
direction from the purified water side to the supply water side. The quality of purified water
produced by Reverse Osmosis is roughly a constant percentage of the feed water. For example, if
the feed water is entering at 50 ppm the purified water may be about 1 to 2 ppm. (96% to 98%
rejection of dissolved minerals). When the feed water is entering at 500 ppm, the purified
water would be from 10 to 25 ppm. Usually a conductance meter is used to measure the mineral
content.

Application Limits
The effectiveness of reverse osmosis treatment for specific impurities and/or dissolved solids
depends on a number of variables. Pressure, temperature, pH, membrane material and the chemical
composition of the feed water all factor into how effective a reverse osmosis element will be in a
specific application. Charts and tables are provided in the Specifications section to help determine
the effectiveness of a reverse osmosis unit in a specific application. General guidelines are provided
to help determine whether a reverse osmosis unit should even be considered. Reverse osmosis
membranes are very well suited to reduce inorganic contaminants. When dissolved in water,
inorganic materials dissociate into positively charged cations and negatively charged anions. These
charged particles tend to be rejected at the membrane. Organic contaminants are a different matter.
Reverse osmosis membranes reject organic contaminants based on their molecular weight. Organic
substances with a molecular weight greater than 300 will generally be rejected at the
membrane.
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Organics with lower molecular weights, such as trihalomethanes, can pass through the membrane.
The large size of viruses and bacteria generally prohibit them from passing through the membrane.
Feed water is input to a prefilter.

2.2.3 POLYMERIC FILM MULTI EFFECT DISTILLATION (PFMED)

PFMED is an energy recovery evaporator which compresses a low-pressure vapour and produces a
low volume of vapour with high pressure and temperature. In PFMED influent is heated with steam
and the vapour produced are compressed and sent to a heat exchanger where it gets condensed and
we get condense water at the outlet. Generally, PFMED is used before MEE to enhance the TDS
concentration of influent. This system is available in polymeric film technology. After RO effluent
is fed into PFMED to remove high volatile compounds which were not removed in the previous
process. In this process water recovered is approximately 65%.
PFMED is available in polymeric film technology with Thermal Vapour Recompresser (TVR) to
reduce energy consumption.
Process Description:
The reject from RO unit is coming to Hardness Removal system. Caustic soda dosed as per the lab
jar test report to maintain pH above or equal to 11. Soda ash dosing pump started. An agitator is
provided for mixing it. Poly dosed to settle down the floc formed in the settler. Settled sludge shall
be transfer to Hardness Sludge tank and further procced into centrifuge dewatering through the
Sludge Thickener. The clear liquid over flows to the PFMED feed tank. Acid dosing is provided to
maintain/ neutralised the PFMED feed pH from 6.0 to 7.0. After removal of Hardness, this reject
water transfer to the PFMED feed balance tanks (as per the requirement).

TABLE 1: CHEMICAL USED IN HARDNESS REMOVAL SYSTEM:

S.N Parameters Range

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1 Hardness 100-150 ppm

2 PH (initial) Above 110

PH (final) 6.5 to 7.5

TABLE 2: CHECK LIST (SET POINTS):

S.N Chemical used Range

1 Caustic Soda 2000 ppm

2 Soda Ahs 1500 ppm

3 Poly 0.4-0.5 ppm

4 Acid 2400 ppm

After removing the hardness from RO reject water, effluent being transfer by centrifugal Transfer
Pump or RO Final Reject Pump P-1803 A/B (1W + 1S) to PFMED feed balance tank as required.
There are 2 Nos. of transfer pump provided on the basis of one working and one standby.

Figure2.9: SCADAs representation of PFMED

There are 3 Nos. of intermediate tanks are provided named as PFMED Feed Balance Tank (T-2101
A/B/C) for respective PFMED –A/B/C units. This PFMED Feed Balance are provided along with

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Level Gauges and level transmitters. Each PFMED Feed Balance tank provided for respective
PFMED Unit. There 2 No. of PFMED feed pump are provided for each PFMED unit on the basis of
one working and one standby. These pumps are provided along with NRV, pressure gauges, strainer
at pump suction, suction and discharge valves.

Figure2.10: PFMED Feed Balance Tank

The PFMED feed pump operated as required to respective PFMED unit. The effluent fed to the
PFMED through the pre-heater- Plate and Frame type Heat Exchanger to conserve the energy or
reduce steam consumption. There are 2 Nos. of PHE provided one side effluent and another side is
hot liquid that is condensate and concentrate

Figure2.11: Heat Exchanger

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2.2.3.1 PFMED- Seal Water Tank

Before going to the PFMED Vessel or recirculation pumps operation, The most important is to know
about seal water. Seal water is required for the PFMED recirculation pump cooling system. Required
flow of Seal water is 4.5 m 3/hr at 2.5 kg/cm2 and the temperature of seal water in the range of 32 –
38 °C. Seal water tank is provided with level gauge and level transmitter which link with SCADA
plant will be shut while water level low inside the seal water tank.

2.3.3.2 PFMED –vacuum pump

Vacuum pump: The two important things in liquid ring vacuum pumps used to create vacuum are
liquid sealant and eccentric impeller.
 Liquid Sealant - most commonly used liquid sealant is water
 Eccentric Impeller - is placed between two port plates which acts as suction and
discharge valve of vacuum pump.

Figure2.12: Vacuum Pump

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2.2.4 MULTI EFFECT EVAPORATION (MEE)

2.2.4.1 VAPORISATION:
Vaporization of an element or compound is a phase transition from the liquid phase to vapour. There
are two types of vaporization:
 Evaporation
 Boiling.
Evaporation is a surface phenomenon, whereas boiling is a bulk phenomenon.
2.2.4.2 MEE-PHE-PRE HEATER
The effluent fed to the MEE through the pre heater- Shell and Tube type Heat Exchanger to
conserve the energy or reduce steam consumption. There are 4 Nos. of Pre-Heater provided in each
unit one side effluent and another side is hot liquid that is condensate.

Figure 2.13: MEE-PHE-PRE HEATER

2.2.4.3 FLASH VESSEL (FV)

The flash vessel provides a simple and efficient method to make use of flash steam in the
condensate recovery system. Inside the flash vessel, the condensate and the emergent flash steam
separate from each other. The steam rising to the top can be fed into a steam line for a technical
application, and therefore the steam generation is reduced in the boiler. Additional savings are
obtained through reduced expenditure on water purification. Successful application of flash vessel
systems depends on the flash vessel's sizing, a stable pressure control, and the effective draining of
the condensate. TLV provides competently designed flash recovery systems complete with a flash
vessel and all the necessary valves to control and safeguard the condensate line.

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figure 2.14 Flash vessel

2.2.4.4 CALANDERIA
The MEE feed is fed through the Pre-Heater to Flash Vessel and Calendria respectively to each
effect. The over flow of 4th Effect send to salt settler for salt recovery and vapour goes to Surface
condenser for condensation of condensate. A Shell & Tube type Heat Exchanger is provided to
condensate the vapour from last effect. Condensate is collected into condensate pot and transfer to
Blended or Condensate tank by condensate pump. Over flow of salt settler is collected in Mother
Liquor Tank and mix along with MEE Feed.

2.2.5 SEWAGE TREATMENT PLANT (STP)

Firstly, we tried to see the whole process that takes place in the plant using flowchart and then begin
observing each treatment places that sewage that already comes from the industries undergoes
through. Sewage Treatment Plant (STP) consists of three treatment systems. This are preliminary,
secondary and tertiary treatment systems. Each treatment systems undergo different process in
treating the waste water.

2.2.5.1Primary treatment system

Preliminary treatment system which is also called physical treatment is used to remove solid
particles. The process begins at Raw Sewage Receiving Chamber which is the receiver of sewages
from industries through a common pipeline. Submersible Raw Sewage Lifting Pump-are used to
transfer the sewages to the next Screening Chambers called Course Bar and Fine Bar. This

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screening chambers which are made up of vertical bars of different gap between the bars are used
for the removal of floating and large size particles.

Figure: 2.15 STP screening chamber

Screened Sewages from the two screening chamber flow by gravity into Grit Chamber through gate
valve. Grit Chamber are used as a sedimentation tank to remove grit consisting of sand or other
solid particles having specific gravity higher than organic solids in wastewater. Since sedimented
grit causes excessive wear and tear on pumps , so the settled grit is disposed of using butterfly valve
along with its pipeline.
2.2.5.2 Secondary treatment system
Secondary Treatment system are biological treatment unit also called Sequential Batch Reactor
(SBR).Pen Stock Gate Valve is used to feed sewage from preliminary to secondary treatment
systems. Since it is biological process we use microorganisms which allows us to reduce biological
oxygen demand (BOD) and chemical oxygen demand (COD) while bubbling oxygen through the
wastewater using air blower and diffuser. Air blowers are devices which are used to supply
pressurized air where as diffuser allows air to encompass most of the space of the Sequential Batch
Reactor. Air blowers are provided with pressure relief valve to reduce the pressure when the air is
highly pressurized. Decanter Centrifuge that separates solid from liquids is used for dewatering and
sludge formation for the settled sludges that comes out of the Sequential Batch Reactor (SBR).We

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saw that they use the sludges from the centrifuge for the purpose of compost for the greenery’s
inside the plant.

2.2.5.3 Tertiary treatment system

In the Tertiary treatment system I saw that the clarified water goes into Multi Grade Filter to remove
suspended solids, dirts, dusts and all visible particles up to 50 microns. After Multigrade filter it
passes through Ultraviolet (UV) which provides rapid, effective inactivation of microorganisms
used in Sequential Batch Reactor (SBR). Ozonator system is the last stage for the water before it
goes into Sewage Treatment Plant treated water tank. In this stage proper disinfection, color
removal and odor removal of treated sewage prior to discharge to users is held. At last I saw that
sewages that undergo three main treatment systems treated and stored in the Sewage treatment
Plant treated water tank.
2.3 SECTIONS OF THE COMPANY WE HAVE BEEN WORKINGON
In Zero Liquid discharge plant (ZLD) has many plants done the process and each process feed to
one another this means the one process output the next process use as an input. As the companies
have different sections of plant they have their own different responsibilities in the plant but I see a
section that are related to my department Electromechanical Engineering. Some of those sections
are,

 Electrical department

 Mechanical department

 Instrumentation department

And some other section but we spent most of the time in this section. We have seen the principal
operation of different machine and also we saw connection with my Electromecanical staff member.
2.3.1 Electrical department
In the electrical maintenance section, all the component-related electrical devices are
found. In this section, the material, which is the electrical, is repaired. Since most of the
systems in the company are electrically controlled and actuated in this section. There are
also different control rooms. PCC (power control center) and MCC (motor control center)

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are important components of electrical distribution systems in the company. Power control
center is an assembly of electrical components that regulates and distributes electrical
power to different loads with in a company. It serves as a centralized control panel for
power distribution and ensures the efficient and safe operation of various electrical
systems. Whereas motor control center is specialized assembly that focuses specifically on
control and protection of electric motors with in a company. It provides a centralized
location for controlling and managing operation of multiple motors. Function of an MCC
includes motor starter, feeder circuits, control and monitoring, safety and protection.
Transformers, boiler, diesel generator and air compressors are also present in the electrical
department. Transformers are used for voltage regulation, power distribution, isolation and
safety efficient energy transfer and so on. Boilers are used for steam generation, diesel
generators are used for standby power or back up power source for the company. Air
compressors are mechanical devices that covert power. Typically from an electric motor
into potential energy in compressed air. This compressed air can then be utilized for
various applications such as powering pneumatic tools.
Motor starters are electrical devices used to control and protect electric motors. Motor
starters are designed to start, stop and control the operation of electric motors. They
provide necessary electrical power and protection for the motor during starting, running
and stopping cycles. Circuit breakers are essential electrical devices designed to protect
electrical circuits and equipment from overloads, short circuits and other electrical faults.
Circuit breakers serve as switches that automatically interrupt the flow of electrical current
in a circuit when abnormal conditions occur.

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2.3.1.1 Tasks We Have Been Executing

During our three month stay on ZLD plant we were involved in different tasks. The first task we
performed was understood the problem and the use of materials which are present in the office.

Figure 2.17 PCC ROOM

Some works we have done in the company are listed below: -

 Direct Online starter (DOL)

 Star Delta starter

 V/f or frequency control

 Stare Delta connection

 Types of circuit breaker

2.3.1.2 Direct Online Starter (DOL)
This is by far the most common starting method available on the market. The starting equipment
consists of only a main contractor and thermal or electronic overload relay. The disadvantage with
this method is that it gives the highest possible starting current. The values are dependent on the
design and size of the motor, but in general, a smaller motor gives higher values than a larger one.

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During a direct-on-line start, the starting torque is also very high, and is higher than necessary for
most applications. The torque is the same as the force, and an unnecessary high force gives
unnecessary high stresses on couplings and the driven application.

Figure2.18: Direct online starter method

outside panel - a) start push button c) auto/manual selector switch
b) stop push button d) trip indication lamp inside panel -
inside panel - a) main circuit breaker c) control mcb
b) contactor

2.3.1.3 Star Delta Starter

This is a starting method that reduces the starting current and starting torque. The device normally
consists of
 Three contractors, Overload relay and a timer for setting the time in the star-position
(starting position).
The motor must be delta connected during a normal run, in order to be able to use this starting
method. The received starting current is about 30 % of the starting current during direct on line start
and the starting torque is reduced to about 25 % of the torque available at a D.O.L start. This
starting method only works when the application is light loaded during the start. If the motor is too
heavily loaded, there will not be enough torque to accelerate the motor up to speed before switching
over to the delta position. When starting up pumps and fans for example, the load torque is low at
the beginning of the
start and increases with the square of the speed.

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Figure2.19: Star Delta starter method

Outside Panel - A) Start Pb C) Auto/Manual Selector Switch

B) Stop Pb D) Trip Indication Lamp
Inside Panel - A) Main Circuit Breaker E) OLR
B) Main Contactor F) Timer
C) Star Contactor G) Control MCB
D) Delta Contactor

2.3.1.4 VFD Starter

A variable frequency drive “VFD” is a semiconductor based motor starter. It can safely start & stop
electric motors as well as fully control the speed of the motor during its operation. It can control the
supply voltage as well as its frequency. When to Use a Variable Frequency Drive? As mentioned
above, a VFD can control both the voltage and the frequency applied to an electric motor. This
means a VFD can be used as a starter, but it can also reduce speed in applications where the motor
workload changes.

Figure2.20: VFD
We use Danfoss VFD in ETP Forwarding Pump, STP Forwarding Pump, RO HPP Pump, SBR
Blower, and RO Booster Pump.

2.3.1.5 STAR DELTA CONNECTION

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 Star connection in motor

A star connection is a connection used in a polyphase electrical device or system of devices in
which the windings each have one end connected to a common junction, and the other end to a
separate terminal.Star connection is preferred for long distance transmission and distribution as it
requires low insulation and has a Neutral which helps to balance the circuit.
Generally, star connection is used where you need a neutral and two separate voltages, like our
distribution system.

Figure2.21: star connection of motor

 Delta connection in motor

An advantage of the Delta connection is higher reliability. If one of the three primary windings fails,
the secondary will still produce full voltage on all three phases. The only requirement is that the
remaining two phases must be able to carry the load. Delta connection is preferred for shorter
distance transmission and distribution as it requires more insulation and has the problems of
unbalanced currents. Delta connection is generally preferred where neutral conductor is not needed
like for transmission of high voltage power.

Figure2.20: Star Delta starter method

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2.2.1.5 TYPES OF CIRCUIT BREAKER

A circuit break is an electrical safety device designed to protect an electrical circuit from damage
caused by an over current or short circuit. A circuit breaker is an electrical switch designed to
protect an electrical circuit from damage caused by over current/overload or short circuit. Its basic
function is to interrupt current flow after protective relays detect a fault.

 Miniature Circuit Breaker (MCB)

A miniature circuit breaker (MCB) automatically switches off electrical circuit during an abnormal
condition of the network means in overload condition as well as faulty condition.
The MCB shall be used up-to 63A

Figure2.22: Miniature Circuit Breaker

 Moulded Case Circuit Breaker (MCCB)

MCCB can protect motors against overload and short circuits. MCCBs can also provide
undervoltages, earth faults and phase failure faults but these features are made available with
additional accessories. The MCCB shall be used from 100A to 63A s

Figure2.23Moulded Case Circuit Breaker

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 Motor Protection Circuit Breaker (MPCB)

MPCBs are used to manually turn on and off electric motors and at the same time protect them from
different types of faults occurring in motors. MPCBs can protect motors against overload, short
circuits, phase loss and under-voltage faults. MPCBs are specially designed for motor protection.

Figure2.24: Motor Protection Circuit Breaker

 Air Circuit Breaker (ACB)

Air Circuit Breaker (ACB) is an electrical device used to provide over current, Earth Fault
protection and Short-Circuit protection.

Figure2.25: Air Circuit breaker

2.3.1.7 Contactors
A contactor is a switching device, widely used for the switching of motors, capacitors (for power
factor correction) and lights. It is a special type of relay, but there is a basic difference between the
contactor and a relay. The contactor is mostly used in applications where higher current carrying
capacity is involved, while the relays are used for lower current applications.

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Figure2.26: Contactor

2.3.1.8 Overload Relay (OLR)

An overload relay works on the heat produced by the excessive overload current. The heat produced
by the overload current is utilized to trip the motor circuit. The function of a thermal overload relay,
used in motor starter circuits to prevent the motor from drawing excessive current which is harmful
to motor insulation.

Figure2.27: Overload Relay

2.3.2Steam Generation Section

Industrial boilers are closed vessels that use a fuel source or electricity to heat water or generate
steam for industrial heating. Boiler is heated until the water is converted into steam at required
pressure. The basic working principle of Electric boiler is very simple and easy to understand. The
boiler is essentially a closed vessel inside which water is stored. Electric Heater Bank turned on and
the heat is transfer to the water and consequently steam is produced in the boiler.in ZLD boiler the
source is electric city. In this plant see how to the boiler give stem to other plants.

Figure2.28: electric boiler

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2.3.2.1 BOILER
Industrial boilers are closed vessels that use a fuel source or electricity to heat water or generate
steam for industrial heating and humidification applications.
 Types of Boiler

1) Based On Design
a. Fire Tube Boiler
b. Water Tube Boiler
2) Based On Heat Source
a. Biomass b. Electric c. coal d. Gas e. Wood
3) Based On Function
a. Hot Water
b. Steam
4) Based On Shell
a. Horizontal
b. Vertical
5) Based On Pressure
a. High Pressure (above 15 psi)
b. Low Pressure
Objective: To produce the steam for the PFMED and MEE unit.

Steam boiler is basically a closed vessel into which water is heated until the water is converted into
steam at required pressure. This is most basic definition of boiler.
The basic working principle of Electric boiler is very simple and easy to understand. The boiler is
essentially a closed vessel inside which water is stored. Electric Heater Bank turned on and the heat
is transfer to the water and consequently steam is produced in the boiler. Then this steam is piped to
the PFMED & MEE plant.

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Figure2.29: BOILER HMI and BOILER HEATER BANKS with Control Panel

Electrical steam boiler is having mainly following main components:

1) Main Shell
2) Heater Tubes
3) Heaters

4) Level Controller
5) Feed Water Pumps
6) Control Panel

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2.3.2.2 Operating Philosophy:

1) Steam boiler utilizes the heat source and converts water in to steam.

2) External heat source, in this case is electrical heaters.

3) Electrical heaters are made from special alloys, which produces heat energy upon external electrical
supply.

4) These heaters are segmented in 8 banks, and each bank is further divided in two segments.

5) Heater bank 1 to 4 are on the front side of the steam boiler, while heater bank 5 – 8 are on the rear
side of the steam boiler.

6) Each Outgoing terminal has 3 phase. Individual heaters are connected in star arrangement. Each
bank has two terminals.

7) You can keep any heater bank OFF by turning off respective selector switch.

8) Set Maximum and Minimum pressure values; which can be entered through HMI.

9) The deviation value is also entered through PLC, which cuts of contactor of the respective heater
bank.

10) When, for the respective bank, the actual pressure value exceeds the set value plus deviation, the
contactor turns off, and hence, turning off the supply to the thyristors.

11) In any case, at pressure more than 12.5 kg/cm2, all banks will turn off.

12) Feed pumps work with water level controller.

13) Water level controller has three probes. Feed pump turns on, when middle level is exposed, and it
turns off when high level is reached.

14) If low level probe is exposed, the boiler gives alarm of low water level and shuts off the heaters.

15) Steam temperature indicator cum controller is also provided.

16) Steam Pressure Transmitter gives signal of current steam pressure to the PLC.

17) PLC then compares it with the set value of the heater bank, and gives 4 – 20 mA signal to the
Thyresistor of the corresponding heater bank.

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18) If pressure is achieved, then corresponding Thyresistor output reduces to zero.

19) If all electrical / electronic interlocks fail, and steam pressure increases, the safety valve will pop up
and releases the steam.

2.3.2 Instrumentation department

We have also seen instrumentation part. Instrument is required to measure and control
different automation processes. We saw different types of transmitters, analytical
instruments, gauges, switches and valves. We also saw different types of measuring
instruments and we can classify them according to their usage.
1. Flow measurement
2. Level measurement
3. Pressure measurement
4. Temperature measurement
2.3.2.1 Flow Measuring Instruments
There are different types of flow measuring instruments in the company. some of them are listed
below

 Magnetic Flow meter

 Vortex Flow meter
 Rota meter
 Inline Rota meter
 Bypass Rota meter

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Magnetic Flow Meter

The principle of operation for the magnetic flow meter is based on the Faraday’s Law of
Electromagnetic Induction. When a conductive liquid flows through the magnetic field, a small
voltage (u) is induced. This voltage is proportional to the velocity of the flow. Flow meter displays
shows Flow and Totalizer (Forward Flow) and Totalizer (Reverse Flow) this is 4 wire instrument.
Two wire for power and two for signal. We use this type of flow meter in ETP Inlet/Outlet, UFRO,
PFMED, MEE, and STP Inlet & Outlet.

Figure2.30 magnetic flow meter

Vortex Flow Meter

Vortex flow meters operate under the vortex shedding principle, where an oscillating vortexes occur
when a fluid such as water flow past a bluff (as opposed to streamlined) body. Vortex Flow meter
used for the measurement of steam. Flow meter measures steam in the unit of Kg/Hr. Flow meter
displays shows Flow, Temperature, Totalizer and Frequency. This is 2 wire instrument. One wire for
power and one for signal. We use this type of flow meter in PFMED A/B/C steam line and MEE
A/B/C steam line.

Figure2.31flow meter

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2.3.2.2 LEVEL MEASURING INSTRUMENTS

Level measuring instruments are divided in to three parts.
 Level transmitter
 Level switch
 Level gauge

LEVEL TRANSMITTER: is simply an instrument that provides continuous level

measurements. Level transmitters can be used to determine the level of a given liquid. At
this company we saw different types of level transmitters. Like
1. Differential pressure type level transmitter

2. Ultrasonic level transmitter

3.Magnetic type level transmitter

Now let’s see them one by one

1. Differential pressure type level transmitter
This instrument calculates level by measuring the differential pressure between the liquid
and gaseous phases of the fluid inside a closed tank. After the liquid level changes, the
pressure received by the diaphragm at the high pressure side flange as a result of the
change, the pressure difference calculated by the transmitter will also change and there is a
linear relationship between them.
2. Ultrasonic level transmitter
This sensor works by “time of flight” principle by using the speed of sound. The sensor
emits a high frequency pulse, generally in the 20 KHZ to 200 KHZ range and then listens
for the echo. The pulse is transmitted then impacts the level surface and is reflected back to
the sensor and then the transmitter for signal processing.

Figure2.31 ultrasonic level transmitter

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3. Magnetic type level transmitter

It consists of a chamber and an internal float in a non-magnetic material compatible with
the liquid. Float containing a magnetic system rides on the liquid level and is coupled to
external visual indicator. It is analog type instrument and we use it in UFRO and PFMED
plants.

Figure 2.32 magnetic type level transmitter

LEVEL SWITCH: it is used to detect the presence or absence of almost any type of liquid
or water. The main purpose for these level switches fall into two main categories; leak
detection and single point level control.
1. Float operated mini level switch
This type of level switch shall be mounted inside bottom or top of the tank .this is operated
through mini float. Its digital input type instrument. When the water level reaches the float
then the motor will get ON/OFF depends up on the connection.

Figure 2.33 float operated mini level switch

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2. Magnetic type level switch

It is digital type input instrument which is used for monitoring and control of liquid levels
in vessels. The purpose of a float level is to open or close a circuit as the level of liquid
rises or falls. It works by buoyancy Principe which states the buoyancy force action on an
object is equal to the mass of liquid displaced by the object’

2.34 Magnetic type level switch

LEVEL GAUGE: are sensing and measuring instruments that are used to detect the level
of a fluid or gas in the tank. There are different types of level gauges.
1.Magnetic type level gauge
This is analog type input instrument. It consists of a chamber and an internal float in
nonmagnetic material compatible with the liquid. Float containing a magnetic system
rides on the liquid level and is coupled to external visual indicator. We use magnetic
type level transmitter in UFRO and PFMED plants in the company.

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Figure 2.35 magnetic type level switch

2. Float and board type level gauge: it consists of a float connected to a pointer through a
rope via asset of pulleys. The float accurately follows liquid level variations in the vertical
direction. As such the pointer is on top position when tank is empty and in bottom position
when full pointer indicates level.

figure 2.36 float and board type level gauge

2.3.2.3 Pressure measuring instruments

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1. Piezoelectric type pressure transmitter: when a force is applied to a piezoelectric

material an electric charge is generated across the faces of the crystal. This can be
measured as a voltage proportional to the pressure. We use this instrument widely in the
company one of the main advantages of piezoelectric pressure sensors is their ruggedness.
This makes them suitable for use in a variety harsh environment and can be used at high

temperatures.

Figure 2.37 piezoelectric type pressure transmitter

2. Pressure switch: is a form of switch that makes electrical contact when a certain set
pressure has been reached on its input. This provide ON/OFF switching from pneumatic
and hydraulic sources. This is device designed to monitor a process pressure and provide
an output when a set pressure (set point) is reached.

Figure 2.38 pressure switch

1 Bourdon tube pressure gauge: is a flattened thin wall closed end tube formed in to a
‘C’ shape or a helix. As pressure is applied to the inside of the tube the oval cross
section becomes more circular and straightens the tube. The tube regains its shape as
fluid pressure disappears.

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2.3.2.4 Temperature measuring instruments

We also saw different types of instruments that measure temperature. For example
1. RTD (Resistance Temperature Detector): is an electric device used to determine the
temperature by measuring the resistance of an electrical wire. This wire is refered to as
temperature sensor. We use this RTD in PFMED and MEE section in the company.

Figure 2.39 RTD

Temperature gauge: the bimetal type temperature gauge is made of two cold welded metal
stripes with different thermal expansion coefficient. The bimetal thermometer measures by
thermal expansion. They are suitable for most applications

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Figure 2.40 Temperature gauge

2.3.3 MECHANICAL DEPARTMENT

In this department different types of maintenances of broken-down materials took place.

We visited mechanical department workshop and watched different types of pumps, like
Centrifugal pump that uses for transfer of the fluid from one place to another. Likewise
submersible pump which is immersed in water and pump out from deep wells to other
wanted places. On the other hand Piston pump is a positive displacement pump used in the
chemical dosing room in the company. Though the flow of this pump is not continuous but
can apply the chemical whenever needed.

2.3.3.1 CENTRIFUGAL PUMP

A centrifugal pump is a type of pump that uses centrifugal force to move fluids. The pump
has an impeller, which is a rotating disk with vanes. The fluid enters the impeller at the
center and is accelerated by the vanes. The fluid then exits the impeller at the periphery,
with increased velocity and pressure. Centrifugal pumps are used in a wide variety of
applications, including water supply, sewage treatment, fire fighting, food processing, and
industrial manufacturing. They are available in a variety of sizes and configurations, to
meet the specific needs of each application.
Here are some of the key features of centrifugal pumps:
 They are relatively simple in design and construction.
 They are efficient and can move large volumes of fluids.
 They can operate over a wide range of pressures and flows.
 They are available in a variety of materials and finishes to suit different
applications.
Centrifugal pumps are typically driven by electric motors, but they can also be driven by
engines or turbines. The motor or engine turns the shaft, which rotates the impeller. The
impeller then imparts centrifugal force to the fluid, which causes the fluid to flow out of
the pump.
Centrifugal pumps are available in a variety of sizes and configurations. The size of the
pump is determined by the amount of fluid it needs to move. The configuration of the
pump is determined by the application. They are versatile and reliable type of pump that is
used in a wide range of applications. They are a good choice for applications where high
flow rates and pressures are required.
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2.3.3.2 PISTON PUMP

A piston pump is a positive displacement pump that uses a piston to move fluids. The
piston reciprocates (moves back and forth) within a cylinder, creating a series of chambers.
As the piston moves down, a chamber is filled with fluid. As the piston moves up, the fluid
is forced out of the chamber.
Piston pumps can be used to move liquids or gases. They are typically used for applications
where high pressures or accurate flow rates are required. Piston pumps are also well-suited
for pumping viscous fluids or fluids that contain solids.
Here are some of the key features of piston pumps:
 They are positive displacement pumps, which means that they move a fixed amount
of fluid with each stroke.
 They can operate over a wide range of pressures and flow rates.
 They are accurate and can deliver precise flow rates.
 They are well-suited for pumping viscous fluids or fluids that contain solids.
Piston pumps are a versatile and reliable type of pump that is used in a wide range of
applications. They are a good choice for applications where high pressures, accurate flow
rates, or the ability to pump viscous fluids or fluids that contain solids are required.
Piston pumps are typically driven by electric motors, but they can also be driven by
engines or turbines. The motor or engine turns the shaft, which rotates the piston. The
piston then reciprocates within the cylinder, moving the fluid. They are available in a
variety of sizes and configurations. The size of the pump is determined by the amount of
fluid it needs to move. The configuration of the pump is determined by the application.
We have also seen different types of valves that control the flow of water. For example ball
valve, butterfly valve, non-return valve (NRV), flat valve and so on. There was breakdown
maintenance of air blower. The wear of the bearing causes the lobes to contact and creates
a disturbing sound. Of course that indicates the workers to identify the problem. As we are
told the problem occurs because of overheating and breakdown of pump seal.
2.3.3 VALVE
Control valves are valves used to control conditions such as flow, pressure, temperature,
and liquid level by fully or partially opening or closing in response to signals received from
controllers that compare a “set point” to a “process variable” whose value is provided by
sensors that monitor changes in such conditions. Control Valve is also termed as the Final
Control Element.

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2.3.3.1 BALL VALVE

A ball valve is a type of valve that uses a ball with a hole through the center to control the
flow of fluids. The ball is rotated by a handle or actuator, which turns the ball 90 degrees.
When the hole in the ball is aligned with the flow of fluid, the valve is open. When the hole
is perpendicular to the flow of fluid, the valve is closed.
2.3.3.2 BUTTERFLY VALVE
A butterfly valve is a type of valve that uses a disk with a hole in the center to control the
flow of fluids. The disk is rotated by a shaft, which turns the disk 90 degrees. When the
hole in the disk is aligned with the flow of fluid, the valve is open. When the hole is
perpendicular to the flow of fluid, the valve is closed.
Here are some additional details about butterfly valves:
 The disk is the most important part of the butterfly valve. It is responsible for
controlling the flow of fluid.
 The shaft is the rotating part of the butterfly valve. It is connected to the disk and
turns the disk when it is rotated.
 The actuator is the mechanism that rotates the shaft. It can be a manual actuator, an
electric actuator, or a pneumatic actuator.
 The seals prevent fluid from leaking from the valve.

2.3.3.3 NON RETURN VALVE
A non-return valve, also known as a check valve, clack valve, one-way valve, or retention
valve, is a valve that allows fluid to flow in one direction only, therefore preventing the
liquid or gas from flowing back upstream of the valve. Non-return valves work
automatically, without the need for any external control. They are typically made of metal
or plastic and are available in a variety of sizes and configurations.
Non-return valves are used in a wide variety of applications, including:
 Pumps
 Water systems
 Sewage systems
There was also breakdown maintenance of STP receiving tank’s pump. Maintenance was
held because of the burned stator coil. The main problem for the damage of the stator coil
was overheating of high temperature. For that we checked resistance and continuity by
using Multimeter. Likewise we checked the insulation of the stator coil by using Megger
insulation tester. Damaged seal was also replaced by another seal in order to avoid or
protect the rotor part from leaking water. On the same day we cleaned the unwanted oil
from the pump. We also identified bearing damage of a centrifuge. There was breakdown
maintenance of the pump key way. Of course it took a lot of time to repair. We also have

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seen decanter centrifuge which separates solids from one or two liquid phases in a single
continuous process. It was done using centrifugal forces that can be well beyond 3000
times greater than gravity. We also learned how important open type impellers are than
closed type. The open type is chosen for simplicity that solids and debris are caught,
maintenance cost reduces and efficiency of the pump also increase. We also saw a jet
pump, that has very high pressure but water comes in a very small hole. Since it was
pressurized water we used it for cleaning purpose of dirty pipes. Apart from this we have
seen a boiler room of the company which is useful for creating steam and the boiler uses
many thyrstors which control electric power and current by acting as a switch.
2.3.3.4 Pneumatic Valve
It consists of Actuator, Valve Limit Switch, and Solenoid Coil. Compressed air from the
compressor is stored in an air tank and then fed through a pipeline system to the necessary
areas of the plant. A pneumatic actuator (for example, an air cylinder) converts the energy
from this compressed air into motion. The motion can be rotary or linear, depending on the
type of Actuator. Pneumatic actuators can be either spring return or double acting. Valve
Limit Switch gives a command (Open or Close) to PLC. When Solenoid Coil is energized,
valve gets open or close.

2.3.4 INDUSTRIAL AUTOMATION

Industrial automation is a set of technologies that uses control systems and devices, such as
computer software and robotics, to enable automatic operation of industrial processes and
machinery without the need for human operators. Industrial automation eliminates the possibility of
human error, reduces costs, saves time, and achieves higher performance.
 Types of industrial automation

Programmable logic Controller (PLC)

Distributed control system (DCS)

 Component of automation

Software- SCADA

Hardware-PLC

Process Logic Controller (PLC)

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2.3.4.1 Programmable Logic controller

PLC is a special form of microprocessor-based controller that uses a programmable memory to
store instructions and to implement functions such as logic, sequencing, timing, counting, and
arithmetic to control machines and processes and is designed to be operated by engineers with
perhaps a limited knowledge of computers and computing languages. PLCs:
 Have interfacing for inputs and outputs already inside the controller

 Are rugged and designed to withstand vibrations, temperature, humidity, and noise

 Are easily programmed and have an easily understood programming language that is
primarily concerned with logic and switching operations.
Typically a PLC system has five basic functional components in Siemens’ automation which is us.
These are central processing unit, power supply unit, input-output module, interface module, and
communications interface. It uses a programmable memory to store instruction and specific function
that include on/off control, timing, counting, sequencing, arithmetic and data handling. We use PLC
and SCADA in ETP, UF-RO,PFMED,MEE and STP. PLC Sensors & Actuators
Device which converts the signal from one form to another.

 Sensors (Input):
Analog: Temperature, pressure, humidity, level, flow, weight…
Digital: Level, push button (emergency stop), position switch, photoelectric sensor.

 Actuator (Output):
Analog: valve, pump, heater, power supply
Digital: Contactor, Electro valve, Switch, On/Off pump
2.3.4.2 Function of CPU

The actual processing of the signals is effected in the central control unit (CCU) in accordance with
the program stored in the memory. Another name of CCU is Central Processing Unit (CPU) The
CPU controls, monitors and supervises all operations within PLC. An internal communications
highway also known as a bus system, carries information to and from the CPU, memory and I/O
units under the control of the CPU.
Distribute control system

The DCS is a system of sensors, controllers, and associated computers that are distributed
throughout a plant. Each of these elements serves a unique purpose such as data acquisition, process

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control, as well as data storage and graphical display. These individual elements communicate with
a centralized computer through the plant’s local area network – often referred to as a control
network. While DCSs are used across the process control industries to supervise complex
production processes, they are more widely deployed at large, continuous manufacturing plants such
as those in the petrochemical industry.

Difference between PLC and DCS

 DCS is a control system that works with several controllers whereas PLC control system
work with single controller.
 PLC is a machine control system whereas DCS is for process control.
 DCS has a wide range of communication, but PLC doesn’t have that much.
 PLC has to go offline to change any parameters. In DCS it can be done online.
 PLC programming is ladder logic, for DCS uses graphical function blocks.
 DCS is a relatively large system while the PLC is a small system.

Supervisory Control And Data Acquisition:

 Supervisory Operator/s, engineer/s, supervisor/s,

 Control Monitoring Remote/Local

 Data acquisition Analog / Digital Access and acquire information or data from the
equipment.

2.3.4.3 Component of SCADA

a) Human Machine Interface (HMI):-It is an interface which presents process data to a human
operator, and through this, the human operator monitors and controls the process.
b) Supervisory (computer) system:- It gathers data on the process and sending commands (or
control) to the process.
c) Communication infrastructure:- It provides connectivity to the supervisory system to the
Remote Terminal Units.
d) Remote Terminal Unit (RTU):- It connect to sensors in the process, converting sensor
signals to digital data and sending digital data to the supervisory system.

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e) Programmable Logic Controller (PLC):-It is used as field devices because they are more
economical, versatile, flexible, and configurable than special-purpose RTUs.
SCADA Application

 Industrial processes: Water Treatment Plant, Chemical, Power generation and

distribution, Metallurgy.

 Nuclear processes: Reactors, Nuclear waste

 Experimental physics: Tokamaks, HEP laboratories What do SCADA provide

 Flexible and open architecture  Basic SCADA functionality
 Alarm Handling and Trending

 Access Control

2.3.5 What Procedure we Have Been Using While Performing Our Tasks
The procedure that we have been using while we performed our task is that depending on the
manual of the company to reduce lose during their operation.

 Preparing plan for activities should have performed during the internship.
 Attending punctually each work in days.
 Prepare a short review of daily activities at the end of each working day.
 Paying attention and asking about anything that is not clear.
 Listen carefully and take notes.
 Reading books and browsing internet to get the needed information out of the company.

2.3.6 What Kind Of Technical Challenges We Have Faced

There are some challenges that we have faced while practicing in ZLD plant during the internship
period .challenges faced me starting from the beginning to end of the program to mention some of
them:

 Sometimes not turn power off while working

 Sometimes not wear appropriate safety clothing
 The bad smell of untreated water hard to adapt the working environment
 It is hard to ask the supervisor when over load in work happens.

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 Difficulties on matching the theoretical knowledge with practical.

 Confusion of work when getting in to the action.
 Some name of the machine and device is not easily understandable.

2.3.7 How Good we Have Been Performing

In the first week we have performing over view all section of the ZLD plant and the process. We
also communicate with employers this was the good beginning to upgrade our communication skill.
The employers were treating our like friendly and they were open to tell everything they know.
While performing my duties we were good because we have a good mentors, the employers also
good and we are not afraid or ashamed anyone them to ask any misunderstanding and also the
practices that we performed after finishing the over view of all the section of the plant helps to
understand further the problems that happens in the plant and how the machine operate.

2.3.8 Measures We Have Taken In Order To Overcame the Challenges

In the first week we have performing over view all section of the ZLD plant and the process. We
also communicate with employers this was the good beginning to upgrade our communication skill.
The employers were treating our like friendly and they were open to tell everything they know.
While performing my duties we were good because we have a good mentors, the employers also
good and we are not afraid or ashamed anyone them to ask any misunderstanding and also the
practices that we performed after finishing the over view of all the section of the plant helps to
understand further the problems that happens in the plant and how the machine operate. The
practices that I have performed are basic motor connection mechanism. Those connections are:
I have taken different measure in order to face my challenges.

 We are collect all ambiguities and question when the supervisor is over loaded then we

 Raised those ambiguities and question at the time he is free.

 To go through with the noise we have using headsets.

 We tried to discuss with team mates, employer, and supervisor about what were difficult to
matching the theoretical knowledge with practical , and also

 We are Practice the control and power circuit of different starting method of motor.

 Also tried to ask question about problems that we are find and tried to understand it clearly
before taking action. And also show our supervisor and formal after completing the task to
be safe.

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CHAPTER THREE

OVERALL BENEFITS AND CHALLANGE OF INTERNSHIP

3.1 overall benefits of Internship

Internship is method of making opportunity for University students on job training, potentially
valuable and explores general career avenues as well as specific. Such arrangements can provide us
with valuable work experience both practical and for resume enhancement and an opportunity to
line up a job before graduation, In addition to securing good work experience. The major benefits
that we get from the internship are classified and stated as below briefly.
3.1.1 In Terms Of Improving Practical Skill
 One importance of internship is making the students practically skilled. Before we join the
host company for internship we have no such deep knowledge about the real work of
industries. The several courses that we were taken in the class deal with the theoretical side
of engineering. Some lectures took the initiative and try to illustrate the practical part of
this field by displaying graphic images in their lecture. This internship program was
exactly what we needed to future the lack of practical skills we had. Generally, internship
helps us to develop the following practical skill.
 To analyses starting method of motor
 Identifying causes of motor failure and Troubleshooting and maintenance
 How to identify the pro Creativity and an innovative approach to solving problems.
 Effective assessment and risk, resources and time management
 Creativity and innovative approach to solving problems.
 The ability to analyze and interpret diverse,
 Critical thinking and the ability to evaluate problem,
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 Effective assessment and management of resources and time;

 Interpersonal sensitivity, persuasiveness and the ability to work as part of a team; 
Awareness of ethical issues and the wider impact of work.

3.1.2 Upgrading Our Theoretical Knowledge

Internship program is not only making students skilled also making students more knowledgeable
on the theoretical part by correlating the practical skill with theoretical knowledge. We have search
different sources to know the operation and properties of different machine or a device. Things in
which we upgrade theoretical knowledge are:

 To know the operation of different machine.

 To design the control circuit of different system
 To control a certain system
 To familiarize more with different sensors that learned in instrumentation I
 To know the process of plant one by one.
 Ability to innovate new machine.
3.1.3 Improving Interpersonal Communication Skill
During the internship period interpersonal communication skill is the best thing because one way of
learning, mutual exchange of ideas, information and skill. Furthermore we can establish mutual
respect with all the staff members peacefully and consideration for one another opinions and input.
In the company, we were engaged during our internship period at ZLD plant. We tried to develop
our interpersonal communication skill by different forms such as speaking, writing and listening. It
has the following advantages;

 To handle information.

 Making productivity more fruitful.

 To become easier to work with staff members.

 To persuade people.

 To improve relationship with others.

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 To understand workers‟ attitude.

 To know the work characteristics in the company

For varies reasons interpersonal skill are crucial. More often than not people lose their jobs because
they are unable to work well with other. One full system should work efficiently with union of so
many professionals by collaborating with each other in order to make good and fantastic work
Finally, what we have observed was to communicate effectively, it is essential that you choose the
suitable medium. Selecting the right communication channel is like shopping in the right store. If
you are not unfamiliar with the terms it is essentially the communication that happens between a
task giver and a task completer.
3.1.4 In Improving Our Team Playing Skill
Even if tasks are done individuals by the respective person at different section of the company, there
are times at which different individuals come together to work for common goals of the company
for increasing productivity. The most important point in team playing skill is just reaching an
agreement from different points on the work to be done. Generally speaking a person with good
team playing skill may have the following qualities and our ambition during the period is try to
achieve and develops as a habit

 Highly reliable at all times.LRNSHIP REPORT IN ETAB SOAP FACTORY 2012 E.C a
good team player at work is someone who is highly reliable at all times and not just for
some time. And they help the team to be on track with excellent performance quality.
 confident communication
An effective team player communicates his ideas clearly and honestly. They respect the opinions
and beliefs of the others on the team.

 Are problem solvers

As a team there will be many challenges that they have to face a good team player is willing to take
any problem in a solutions oriented method

 Communicates constructively

 Listen actively

 Functions as an active participant

 Shares openly and willingly

 Cooperates and help others

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 Shows commitment to the team

 Works as a problem solver

 Treats others in a respectful and supportive manner

3.1.5 In Terms Of Improving Our Leadership Skill

The Leaders in ZLD plant follow a good leader principle like honest, resolve problems in good
manner, takes a serious commitment, respect the idea of the employer, willingness to accept
comments, and makes the employer active at work and so on. During our stay we can learn those
good leader principles. Leadership is a process of leading the careers of the company. Problems in
the company Come in all size, shape and color in different period of time. Thus, a person who is in
the Position of leadership seeks optimal solution to problems and should be smart enough to
manage those individuals whom he/she is leading. What was gained from the internship regarding
improving
Leadership is that to inspire workers into higher levels of teamwork, There are:-
 Technically proficient.
 Seek responsibility for action.
 Make sound and timely decision.
 Know peoples and look out for their well-beingRNSHIP REPORT IN ETAB SOAP F
 Develop a sense of responsibility in workers.
 Ensure the tasks were understanding, supervise and accomplished.
Finally, what we understand is becoming a leadership is not an easy task because it takes a
conscious commitment, needs to be experienced and consistent effort to develop one's leadership
skill. But on the positive side, anyone who is willing to make the effort can become a good leader.
3.1.6 In Terms Of Understanding about Work Ethics and Related Issues
In today's complex world, ethical conduct of workers is very important for developing healthy
working environment and increasing productivity. The work ethic is a cultural norm that advocates
being personally accountable and responsible for the work that one does and is based on a belief
that work has intrinsic value. The term is often applied to characteristics of People, both at work and
at play. These involve Attitude, behavior, respect, communication, interaction, and how one gets

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along with others. The following are some of the common professional ethical principles what we
gained in the internship period.

 Punctuality-means being on time which is companies working time and to complete a

given task within the given period.

 Cooperation:–worker should interact and cooperate with each other while working. That is
because it is through each system problems could be easily solved.

 Reliability:–the worker should be qualified for the part he/she is supposed to be

Performing.

 Integrity He/she must have appropriate skill and knowledge for the task assigned.

 Be responsible in analyzing and interpreting gathering of data.

3.1.7 In Developing Our Entrepreneurship Skill
While practicing in ZLD plant we realized that creativity and problem solving is one of the Starting
points of entrepreneurs. This internship motivates us not to be employee because it enables us to
know more about our career, the real challenges, and way of business establishment in our
profession. A wide range of skills are seen as entrepreneurial and useful to entrepreneurs, these
include both personal traits and skills:

 Management skills - the ability to manage time, people (both ourselves and others), the
ability to work both as part of a team and independently.

3.2 Challenges We Have Been Facing While Performing Our Tasks

 Learning the ropes. Water treatment is a complex process with many moving parts. As an
intern, you will need to learn a lot of new information in a short amount of time. This can be
challenging, but it is also an opportunity to learn a lot and gain valuable experience.

 Being a team player. Water treatment is a team sport. You will need to be able to work
effectively with others, both as a subordinate and as a leader. This can be challenging, but it
is essential for success in the water treatment industry.

 Dealing with safety hazards. Water treatment plants can be dangerous places. You will need
to be aware of the safety hazards and take steps to mitigate them. This can be challenging,
but it is essential for your own safety and the safety of others.

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 Managing your time effectively. Water treatment internships can be demanding. You will
need to be able to manage your time effectively in order to complete your assignments and
learn as much as possible. This can be challenging, but it is essential for success in any
internship.

3.2.1 Counter Measures for the Challenges

Despite these challenges, being an intern in a water treatment company can be a rewarding
experience. You will have the opportunity to learn about a vital industry, gain valuable skills, and
make a real difference in the world.

To overcome these challenges we took some steps

 We were proactive which is we don't wait to be told what to do. Take initiative and ask
questions.

 We paid attention to what ours advisor and coworkers are telling us.

 We were willing to learn and open to new ideas and ways of doing things.

 We were trying to keep our safety by following safety procedures.

 We also tried to Have a positive attitude and be willing to work hard.

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CHAPTER FOUR

Design of Electrical Scissor Lift

Abstract
In the industry, as a lifting system, the electrical scissor lift system is commonly used. This system
is mainly preferred to do Load lifting and lowering activities, cleaning services, and maintenance-
repair activities. This project focuses on the design of an electric scissor lift which uses Arduino as
a microcontroller for precise control, monitoring of the scissor lift’s operation. The Arduino-based
electric scissor lift is a versatile and efficient mechanism designed for vertical motion applications,
enabling the controlled elevation and descent of various loads.
The scissor lift's design incorporates a scissor-like mechanism composed of linked arms, which
expand and contract in a coordinated manner to raise or lower the platform. Each arm's motion is
driven by a combination of electric motors, force rod and linear actuators. An Arduino
microcontroller serves as the brain of the system, orchestrating the synchronized movement of the
arms and ensuring accurate positioning. The Lifting System Integral components include push
buttons, an Arduino microcontroller, motor drivers, electric motors, a scissor mechanism, and a
stable platform. The push buttons serve as user interfaces, relaying commands to the Arduino. The
Arduino processes these commands and translates them into motor control signals through motor
drivers, resulting in the coordinated motion of the scissor arms.
The functionality of the electric scissor lift centers around manual control through push buttons.
Users press dedicated buttons to initiate the lift's upward or downward motion. The Arduino
interprets these inputs, orchestrating the activation of the electric motors. The motors, connected to

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the scissor mechanism, drive the arms to expand or contract, raising or lowering the platform
according to user commands.

4.1 Statement of the problem

The utilization of ropes, scaffolds, and traditional mechanical scissor lifts to access elevated heights
presents numerous limitations. These include factors such as load capacity restrictions, discomfort,
time consumption, and significant energy expenditure. To address these challenges, the concept of an
electrically powered scissors lift has emerged as a viable solution.

In the context of a Zero Liquid Discharge (ZLD) plant, the transportation of chemicals used in
sewage treatment, such as sulfuric acid and hydrochloric acid, which possess strong acidic
properties, often requires manual labor to reach elevated heights. Similarly, heavy materials like
submersible pumps and motors necessitate the physical effort of workers to lift and transport them to
the desired locations within the plant.

By incorporating an electrically powered scissors lift, these limitations can be effectively overcome.
The lift's enhanced load capacity enables the transportation of heavier loads, alleviating the strain on
workers. Moreover, the introduction of electric power streamlines the lifting and positioning process,
significantly reducing time consumption and minimizing the energy expended by manual labor.

The integration of an electrical power system into the scissors lift offers increased convenience,
efficiency, and safety when navigating elevated heights within the ZLD plant. The reliance on
manpower for lifting and transporting materials is greatly reduced, allowing for improved
productivity and a more ergonomic work environment.

4.2 Objectives of the Project

4.2.1 General Objective
The general objective of this project is to design an electrically powered scissors lift in the context of
a Zero Liquid Discharge (ZLD) plant is to enhance efficiency, productivity, and safety by automating
the transportation of heavy materials and chemicals to elevated heights, thereby reducing the reliance
on manual labor.

4.2.2 Specific Objective

The specific objectives of this project are :-

 To develop a mechanical design on solidworks that includes motor, screw

force rods, base and top plate.
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 To develop circuit design on Proteus consisting of Arduino, DC motor,

battery, push buttons.

 To generate Arduino code for controlling the system.

 To simulate the system on Proteus by connecting all the necessary

components that will rotate the motor in the desired direction according
to the type of push button pressed

4.4 Significance of the Project

The advantages of the electric scissor lift are:-

 Increase Efficiency: Streamline the lifting and positioning process by

implementing an electric power system, reducing time consumption and
minimizing the energy expended by manual labor.

 Enhance Safety: Reduce the risks associated with manually handling heavy
materials and chemicals at elevated heights by replacing it with an
automated system that prioritizes safety measures.

 Optimize Productivity: Enable faster and more efficient transportation of

used in sewage treatment, such as sulfuric acid and hydrochloric acid, by
eliminating the need for manual labor and providing a reliable and
automated solution

4.5 Scope and Limitation of the Project

4.5.1 Scope
The scope of this project are :-
1. Applications: The concept of a electric scissor lift has a broad scope and can be applied
in various areas in ZLD plant for example in lifting sewage treatment chemicals, for
transporting pumps and motors.
2. Control Systems: The concept includes the integration of control systems, such as
Arduino microcontroller to automate and optimize the operation of the scissor lift.
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4.5.2 Limitations
 It only operates in vertical direction. They typically have limited horizonal
reach and maneuverability.
 Weight restriction: exceeding the weight limit can affect the lifts stability and
pose safety risk.
 Power source dependency: electric scissor lifts relay on electricity to operate,
which means they require access to power outlets or batteries for operation.

4.6 Literature Review

Humanity's relentless pursuit of progress and improvement has driven scientific and
technological advancements, shaping our dynamic world. The development of scissor lifts
has been the result of decades of research and innovation. Throughout history, numerous
scientists and engineers have made significant contributions to the field of scissor lifts.
This literature review aims to provide an overview of their work and serve as a foundation
for the design and construction of a hydraulic scissors lift.
Balkeshwar Singh, Anil Kumar Mishra(2015), Studied that Scissor lifts, a staple of
mechanical design, especially in competitive robotics, are a type of linkage that can be
used to raise a load to some height, when acted upon by some force, usually exerted by an
actuator. The position of this actuator, however, can affect the mechanical advantage and
velocity ratio of the system Hence, there needs to be a concrete way to analytically
compare different actuator positions.
Dr. Ramachandra C G, Krishna Pavana(2013), all current research into the analysis of
scissor lifts either focusses only on the screw jack configuration, or derives separate force
expressions for different actuator positions. This, once again, leaves the decision between
different actuator positions to trial and error, since the expression to test the potency of the
position can only be derived once the position is chosen.
M.M.Noor, K. Kadirgama, M.M. Rahman(2008), proposes a derivation for :general force
expression, in terms of a few carefully chosen position variables, which can be used to
generate the force expression for any actuator position. Hence, this expression illustrates
exactly how each of the position variables (called a, b and in this paper, as defined later)

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affect the force output, and hence can be used to pick an appropriate actuator position, by
choosing values for the position variables that give
the desired result.
Helmi Rashid and et.al(2013), Scissor Lift is a simple mechanical device used to raise
element or object from ground level to certain height to perform a specific work with
maximum load and minimum efforts, This project describes the design as well as analysis
of a mechanical scissor lift which works on the principle of screw jack. The design will be
developed keeping in mind that the lift can be operated by mechanical means so that the
overall cost of the scissor lift is reduced. Also such design can make the lift more compact
and much suitable for medium scale work.
Jaydeep M. Bhatt, Milan J. Pandya(2012), Conventionally a scissor lift a or jack is used for
lifting a vehicle to change a tire, to gain access to go to the underside of the vehicle, to lift
the body to appreciable height, and many other applications. But in this case along with
lifting a vehicle we are also going to make an effort to move the vehicle to a short distance
by incorporating roller mechanism Finally, the analysis will be carried out in order to check
the compatibility of the design values.

4.6.1 Scaffolds
Scaffold allows workers to transport themselves and their materials to elevated heights, usually up
and down in an unfinished building. Scaffolds are designed to allow workers get to elevated heights;
they are used in building sites and construction sites but used mainly in building sites. Scaffold is
cross section of pipes, irons or woods which are arranged in such a way that workers or operators
can climb on the arranged pipes to get to elevated heights.

Scaffolds cannot be adjusted automatically and they only can remain fixed the way it is arranged
unless rearranged. The tubes are either steel or aluminum, although composite scaffolding using
filament wound tubes of glass fiber in a nylon or polyester matrix. If steel, they are either black” or
galvanized. The tubes come in a variety of length and a standard diameter of 48.3mm. The basic
difference between the two types of tubes is the lower weight of aluminum tubes (1.7kg/m as
opposed to 4.4kg/m) and also a greater flexibility and so less resistance to force. Tubes are generally
bought in 6.3m length and can be cut down to certain typical sizes. Boards provide a working
surface for users of the scaffold. They are seasoned wood and are very strong. Scaffolds for
increased height are preferably made of hardened materials like metal pipes. After arranging the

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pipes, a flat material usually made of wood is placed on top so that the worker can stand comfortable
on top.

Fig 4.1 Scaffolds

4.6.2 Boom Lift

Boom lifts are used for lifting materials especially on construction sites, they are designed to carry
heavy equipment and materials from one place to another. They are usually connected to cars or
trucks that move from one place to another. Boom lifts can lift materials and equipment high to
height so great that carrying this equipment by other means will almost be impossible.

According to material handling equipment from ask search engine, Boom lifts can move vertically,
horizontally and sideways and some can even rotate depending on the circumstance. Boom lifts are
very complex iron design and the jointed parts should be lubricated to reduce friction and improve
efficiency. Boom lifts are formed mainly in construction sites and building sites. They are also
utilized by Electrical companies and firms.
They are very expensive and are not available in crude or semi mechanized type of production.
Boom lift possess advantage over other types of lifts because it can lift heavy materials, keep them at
elevated heights for a long period of time; rotate and the lift span of the equipment is long. Boom lift
can fold together to become compressed and portable.

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There are two basic types of boom lifts: straight boom lift and articulated boom lift. These units are
often hydraulically powered.

4.6.2.1 Straight Boom Lift

Straight boom lifts are generally used for jobs that required a high reach without obstruction. The
machines turntable can rotate 360o with an extensible boom that can be raised vertically to below
horizontally. The operator can maneuver and steer the vehicle while the boom is fully extended. It is
available in gas, propane or diesel-powered models with two- or four-wheel drive.

Fig 4.2 Straight boom lift

4.6.2.2 Articulated Boom lift

Articulated boom lifts are used for jobs that require reaching up and over obstacles to gain access to
a job not easily achieved by a straight telescopic boom. This lift is nearly identical to the straight
boom lift in every aspect; except in the boom’s ability to articulate. Articulation points on the boom
allow it to bend in any number of different directions enabling it to maneuver around various
obstacles on a job site. Boom lifts can be equipped with out riggers to stabilize the unit while the
boom is fully extended.

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Fig 4.3 Articulated Boom Lift

4.6.3 Mechanical Scissor Lift

The mechanical scissors lift is used for lifting materials especially on construction sites. This is one
of the most recent advancement on scissors lift. There, the lift utilizes a belt drive system connected
to a load screw which constructs the “X” pattern on tightening and expands it on loosening. The lead
screw actually does the work, since the applied force from the wheel is converted to linear motion of
the lift by help of the lead screw. This can be used to lift the working and equipment to a height.
A general knowledge however, regarding screws will reveal the loss due to friction in the screw
threats. Therefore, the efficiency of this device is low due to losses in friction. Also, the power
needed to drive the machine is manual, and much energy is expanded to achieve a desired result. Its
suitability however, cannot be overemphasized as it can be used in almost every part of the country
whether there is availability of electricity or not.

Fig 4.4 Mechanical Scissor Lift

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4.6.4 Hydraulic Scissor Lift

Scissors lifts has developed overtime, and at each stage of its development, critical problems are
solved. The hydraulic type, but this time, the load screw is replaced by a hydraulic ram powered by a
pump and on electric motor and generator. One outstanding feature about this design is its
independent operation and increased efficiency. Fluid power is one of the greater form of power
where small input results in a very large output. This scissors lift can be handled by one person to a
place of use, and power the generator.
The lift does not lifting immediately, the operators climbs on the platform and switches open the
hydraulic circuit thereby leading to an upward extension. When the required height is reached the
circuit is closed, and lifting stops the control panel or station is located on the top frame. When work
is done, the scissors lift is folded by hydraulic means and handled back to the point of collection

Fig:4.5 Hydraulic Scissor Lift

4.6.5 Electric Scissor Lift

Electric scissor lifts have gained significant prominence in various industries due to their ability to
efficiently and safely elevate workers and materials to desired heights. These lifts are powered by
electricity, offering several advantages over their counterparts. This article provides an overview of
electric scissor lifts, discussing their design, operation, benefits, and applications.

Electric scissor lifts are typically designed with a scissor-like mechanism, composed of linked
folding supports in an "X" pattern. This design allows for vertical displacement when the supports
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extend or retract. The scissor lift platform is attached to the top of the mechanism, providing a stable
working surface.
The key components of an electric scissor lift include an electric motor, electric drive system, control
panel, safety features, and a platform with guardrails. The electric motor powers the lift's movement,
while the drive system enables smooth and controlled vertical motion.
Electric scissor lifts are operated using user-friendly controls located on the lift or control panel.
These controls allow operators to raise, lower, and maneuver the lift as needed. The controls
typically include buttons or switches for vertical movement and directional steering. Additionally,
safety features such as emergency stop buttons and limit switches ensure safe operation.
Electric scissor lifts find extensive use across multiple industries. They are commonly employed in
construction projects for tasks such as electrical installations, painting, and ceiling repairs. In
warehousing and logistics, electric lifts assist with inventory management, order picking, and stock
replenishment. Furthermore, they are valuable tools in maintenance and repair activities, both
indoors and outdoors.

Fig: 4.6 Electric Scissor lift

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4.7 Methodology
The methods that we used to do our project are described below. The first step was to create
a proper time schedule outlining what we would do. Then we gathered various information
for our project from various sources, such as articles, books, and the internet.
When the desired push button is pressed i.e., up or down button to lift the object, the Arduino
microcontroller processes these commands and translates them into motor control signals through
motor drivers. According to the given instruction the motor starts to rotate either in clockwise or
anticlockwise direction. The motor is coupled with Ball screw and also the Ball screw is mounted
with Ba;in order to convert the rotational motion of the motor to translational motion of the force
rod. This results in the coordinated motion of the scissor arms.

4.7.1 System components

4.7.1.1 Mechanical Components
The electrical scissor lift consists of different mechanical components. These are:-
Base plate: serves as a foundational component of an electric scissor lift, forming the stable
platform upon which the entire lift structure rests. As a critical element of the lift's design, the base
plate plays a pivotal role in ensuring structural integrity, stability, and load-bearing capacity.
The base plate serves as the primary point of contact between the lift and the ground or floor
surface. It provides a stable foundation that supports the weight of the scissor mechanism, platform,
and any loads the lift may carry. The base plate's flat and level surface contributes to the overall
stability of the lift, preventing tilting, wobbling, or toppling during operation. The base plate will be
made of
Mild Steel due to its high strength, durability, and load-bearing capacity. It's well-suited for heavy-
duty applications and offers excellent resistance to impacts.

Upper plate: is a fundamental component within an electric scissor lift, serving as the uppermost
platform that supports loads and provides a stable surface for tasks performed at elevated heights.
The upper plate is the point of contact for the loads being lifted and the area where work is
performed. The upper plate is designed to securely hold the loads being lifted, ranging from tools
and equipment to personnel. It must withstand both static and dynamic loads while maintaining
stability.

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The upper plate provides a stable and level surface for tasks performed at elevated heights. This is
particularly important in applications such as maintenance, construction, and material handling.
Mild Steel is preferred for its strength and durability. It's suitable for heavy-duty applications and
offers the robustness needed for lifting heavy loads.

Scissor Link: is responsible for the lift structure to move up and down. Scissor links are the
primary mechanical components that define the distinctive scissor-like structure of electric scissor
lifts. These interconnected links are pivotal in enabling controlled vertical movement, and stability
in scissor lifts.
Scissor links serve as the essential framework for electric scissor lifts, allowing for efficient vertical
motion and load distribution. The pivotal function of scissor links is to facilitate vertical movement.
When the lift's electric motors activate, they drive the scissor arms to extend. As the arms extend,
the scissor links rotate at their hinges, causing the links to unfold. This results in the platform's
elevation.

Fig: 4.7 Scissor Link

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Ball Screw : is a mechanical component that plays a pivotal role in translating rotary
motion into linear motion with high efficiency and precision. In electric scissor lifts, ball
screws are often utilized to convert the rotational motion of electric motors into smooth
vertical movement of the scissor arms, thereby raising or lowering the lift's platform.
The operation of ball screw involve the interaction between a threaded shaft (screw) and a
ball nut. The ball nut contains recirculating balls that are captured between the nut and
screw threads. As the motor drives the screw's rotational motion, the balls move along the
grooves between the threads, causing the ball nut to move linearly along the screw's axis
causing the scissor links to move up and down.

Fig: 4.8 Ball Screw

Ball Nut: is a crucial component that forms an integral part of ball screw mechanisms
used in electric scissor lifts. This mechanical element plays a key role in converting rotary
motion into linear motion, facilitating precise and smooth vertical movement. Ball nuts are
pivotal in transforming the rotational motion generated by the ball screw into the linear
movement needed for extending or retracting the scissor arms, which ultimately raises or
lowers the lift's platform.

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As the ball screw rotates, the recirculating balls of the nut roll along the threaded grooves
of the screw. This motion induces linear movement in the ball nut, causing it to move along
the length of the ball screw. This results the extension and contraction of the scissor arms.

Fig: 4.9 Ball nuts

Bolt and Nuts: are fundamental fasteners that play a critical role in the construction and
assembly of electric scissor lifts. These threaded components are essential for securely
joining different parts of the lift's structure, ensuring stability, safety, and reliability. Bolts
and nuts are used to connect various components, including scissor links, base plates,
upper platforms, and other structural elements. They contribute to the overall stability and
structural integrity of the lift.
By securely fastening parts together, bolts and nuts help evenly distribute loads and
stresses across the lift's framework, preventing localized stress concentrations. Properly
fastened bolts and nuts ensure that the lift's components remain securely attached during
operation, preventing any dislodgment or potential hazards.
The use of bolts and nuts allows for easier disassembly and reassembly during
maintenance, repairs, or component replacement. Hex bolt and nut are commonly used in
electric scissor lifts.

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Fig:4.10: Bolt and Nut

4.7.1.2 Circuit components

The electrical circuit components of the electric scissor lift. Here are the components as
follows:
Push button: are simple yet essential components used for controlling various devices,
systems, and machinery. These switches are designed to be activated by pressing them,
completing an electrical circuit and triggering a specific action. Push buttons are widely
used in electric scissor lifts and numerous other applications, providing convenient and
user-friendly control mechanisms.

Fig 4.11: Push button

Resistor: is an electrical component that limits or regulates the flow of electrical current in
an electronic circuit. These passive components offer resistance to the flow of electrons,
thereby influencing the behavior of current and voltage in a circuit. They restrict the flow

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of electric current in a circuit, preventing components from receiving excessive current that
could lead to damage or malfunction.

Fig: 4.12 Resistor

DC Motor: is an electrical device that converts electrical energy into mechanical motion.
It operates using direct current, where the flow of electric charge is unidirectional. DC
motors are widely used in a variety of applications due to their simplicity, ease of control,
and ability to provide precise speed and torque regulation. It consists of an armature, stator,
commutator, and brushes, and operates based on the interaction of magnetic fields.

Fig: 4.13 DC Motor

Power Supply: is a critical component that provides the necessary electrical energy to
operate the lift's various components, including motors, control circuits, and more. A
dedicated DC power supply provides a steady and regulated direct current voltage, suitable
for powering DC motors, control circuits, and other components in the scissor lift.
Arduino: refers to both a hardware platform and a software environment that enables users
to create, prototype, and program various electronic projects and interactive devices. The
Arduino software environment provides a platform for writing, compiling, and uploading

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code to the Arduino board. It includes an Integrated Development Environment (IDE) that
simplifies the process of programming and interacting with the hardware.
The Arduino hardware consists of a microcontroller board with various input/output pins
that can be used to connect sensors, actuators, and other electronic components. The board
is equipped with a microcontroller, which is essentially a small computer that can execute
programs and interact with the physical world through its pins.

Fig: 4.14 Arduino

Flow chart of the system

Here, below describes the flow chart of the overall system of the electrical scissor lift.

Start

Component
design and
circuit
configuration
Modifica
tion of
Model
Component
assembly

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System setup
No
satisfactory

Yes

Execution
and
evaluation

Circuit Design and Working Principle

The circuit diagram of the electric scissor lift is shown below:

End

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BAT2

12V

ARD1

16 8 U2

ON
Reset BTN

www.TheEngineeringProjects.com
2 3
IN1 VSS VS OUT1
7 6
IN2 OUT2
AREF 1
EN1
13
PB5/SCK
12
RESET PB4/MISO 9
11 EN2
~PB3/MOSI/OC2A 10 11
10 IN3 OUT3

GND
VCC ~PB2/SS/OC1B 15 14
9 IN4 OUT4
GND ~ PB1/OC1A 8
PB0/ICP1/CLKO
L293D

ATMEGA328P-PU
1121
7
ANALOG IN

PD7/AIN1
6
A0 ~ PD6/AIN0
PC0/ADC0 5
A1 ~ PD5/T1
PC1/ADC1 4
A2 PD4/T0/XCK
PC2/ADC2 3
A3
PC3/ADC3 ~ PD3/INT1 2
A4 PD2/INT0
PC4/ADC4/SDA 1
A5 TX PD1/TXD
PC5/ADC5/SCL 0
RX PD0/RXD

ARDUINO UNO

R4
1k

R5
1k

Upon pressing the designated push button, like the up or down button designed for
elevating the object, the Arduino microcontroller comes into action. It processes these
input commands and translates them through motor drivers, thereby generating control
signals for the motor. This results in the motor commencing its rotation, determined by
whether it's set to rotate clockwise or anticlockwise based on the instruction.

The motor is intricately linked with in practical with a ball screw and nut. The ingenious
purpose of this configuration is to ingeniously transform the rotational motion of the motor
into the linear translational motion of the force rod. As a direct outcome, this orchestrated
maneuver translates to the synchronized motion of the scissor arms, which work in
harmony to execute the desired lifting or lowering action.
Software requirement
We made use of the versatile Proteus Design Suite 8.13 software for conducting our
simulation activities. In addition to this, we skillfully composed the necessary code using

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the Arduino Integrated Development Environment (IDE). This seamless combination of

utilizing the software and coding platform allowed us to achieve a comprehensive and
effective simulation process.
Conclusion
It can be concluded that the circuit design for the electric scissor lift that we have aimed
was successful. A push button, motor, resistor, Arduino uno R3, Motor Driver, Power
supply make up the system. The Aim of this design is to make a user friendly interaction
between the person and the system in the lifting system environment. This minimizes time
and enables fostered transportation.

CHAPTER FIVE

Material Selection and Design Analysis for the Proposed Work

5.1Material selection and Properties

Material selection plays a very important role in machine design. For example, the cost Of
materials in any machine is a good determinant of the cost of the machine. More than the cost is the

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fact that materials are always a very decisive factor for a good design. The choice of the particular
material for the machine depends on the particular purpose and the material for the machine
depends on the particular purpose and the mode of operation of the machine components. Also. it
depends on the expected mode Of failure Of the components.

Engineering materials are mainly classified as:

I. Metal and their alloys, such as iron, steel, copper, aluminum etc.

2. Non-metals such as glass. rubber, plastic etc. metals are further classified as ferrous metals
and non-ferrous metals.
Ferrous metals are those metals which have iron as their main constituent, such as cast iron,
wrought iron and steels.

Non-ferrous metals are those which have a metal other than iron as their main constituent, such as
copper, aluminum, brass, tin, zinc etc.

For the purpose Of this project, based on the particular working conditions machine component
were designed for only the ferrous metals have been considered.

Also, certain mechanical properties of metals have greatly influenced our decisions. These
properties include:
Strength: it is the ability Of a material to resist the externally applied force Without break down or
yielding the internal resistance offered without break down or yielding the internally applied forc•c•
is called Stress.
Stiffness: it is the ability of a material to resist deformation under Stress. Elasticity: it is the
property of a material to regain its original shape after deformation when the external forces are
removed.
Plasticity: it is property Of a material Which retains the deformation produced under load,
permanently.
Ductility: a very important property of the material enabling it to be drawn into wire with the
application of a tensile force. A ductile material is both strong and plastic. Ductile materials
commonly used in engineering practical (in order Of diminishing ductility) are mold steel, copper,
aluminum, nickel, zinc tin and lead.

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Malleability: it is a special case of ductility which permits materials to be rolled or hammered into
thin sheets. A malleable material is plastic but not 80 essentially strong. Examples include; lead son
steel, wrought iron, wrought iron, copper and aluminum in order of diminishing malleability.

Toughness: it is the property of a material to resist fracture due to high impact loads like hammer
blows, when heated. This property decreases.

Brittleness: it is the properties of a material opposite to ductility, it is the property of breaking of a

material with little permanent deformation when subjected to tensile load, brittle materials snap Off
Without giving any sensible elongation. Cast iron is a brittle material.

Hardness it embraces difference properties such as resistance to water. scratching, defortnation and
machinability etc. it also measure of the ability of a metal to cut another metal.

5.2 Analysis of mechanical property requirement of essential machine

components
It is necessary to evaluate the particular type of forces imposed on components with a view to
determining the exact mechanical properties and necessary material for each equipment. A very
brief analysis of each component follows thus:
1. Scissor Arm
2. Top Platform
3. Base Platform
4. Ball Screw and Nut
5. Motor
6. Wheel

Scissors Arms: this component is subjected to buckling load and bending load tending to break or
cause bending of the components. Hence it's based on strength, stiffness. plasticity and hardness. A
recommended material is stainless steel.

Top Platform: this component is subjected to the weight of the workman and his equipment, hence
strength is required, the frame of the plat form is mild steel and the base is wood.

Base platform: this component is subjected to the weight of the top platform and the scissors arms.
It is also responsible for the stability of the whole assembly, therefore strength. Hardness and
stiffness are needed mechanical properties. Mild steel is used.

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Ball Screw and Nut: The screw shaft of ball screw is typically made from stainless steel
for strength and wear resistance. Thread inserts are often crafted from hardened steel to
ensure durability. The nut body is fashioned from stainless steel to provide strength and
wear resistance. For smooth motion and wear resistance, the ball return system employs
materials like steel.

Motor: For an electric scissor lift, the choice of motor depends on various factors such as
load capacity, lifting speed, power efficiency, control requirements, and operational
environment. DC motors are widely used in scissor lifts due to their simplicity,
controllability, and efficiency. Brushless DC (BLDC) motors are preferred in our design
due to their efficiency, longer lifespans, and require less maintenance.

Wheels: the wheels are position at the base part Of the scissors lift and enable the lift to
move from one place to the other without necessary employment of external equipment
like car.

5.3 Choice of stainless steel and mild steel

Stainless Steel: these are steel with high rust and corrosion resistance to meet specific
application requirements. They also have high strength and toughness.

It is an alloy Of iron With about chromium and Other metals like nickel, molybdenum etc. the
properties of rust and corrosion resistance. toughness and strength, aesthetics and how coefficient of
friction were considered to meet all requirements and the choice of stainless steel for the scissors
members.

Mild Steel contains 0.05 to 0.3 percent carbons it has for almost all purpose replaced wrought iron,
its greater strength giving it under viable advantages. Mild steel can be rolled, wielded and down. It
can even be east, though not very successfully. Among its application are plates for ship, building,
bicycle frame tubes, mesh work, bolts, nuts, studs etc. solid and hollow constructional sections,
sheet metal parts and steel cæstings such as flywheels and locomotive wheel centers.

Design Analysis
Design Consideration
In this section all design concepts developed are discussed and based on evaluation criteria and
process developed, and a final here modified to further enhance the functionality ofthe design.
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Considerations made during the design and fabrication ofa acting cylinder is as follows:

a. Functionality of the design

B Manufacturability, Economic availability, cost of materials

Geometric Analysis
Figure 2, shows geometry of the scissor lifting machine in raised position, which shows the various
dimensions of the links including their orientation at this position.

Fig 5.1 :Geometry of the scissor lift in raised position

Considering the upper position (Figure 2)

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l 2 2
m + r
2 =
( 1)

Where, l = the length of the arm

m = 1/2 of the distance between the arm in raised position
r = 1/4 of the height of the scissor in raised position

The maximum arm/linkage angle (𝛉max)

The maximum angle between the links and an imaginary horizontal line occurs at the maximum
lifting height. Considering the lifted position (Figure2)

𝛉max = Opposite/ hypotenuse

𝛉max = sin-1 r

l /2

Figure 5.2, shows geometry of the scissor lifting machine in lowered position, which shows the
various dimensions of the links including their orientation at this position.

Fig.5.2. Geometry of the scissor lift in lowered position

Considering the lowered position (Figure 3)

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𝛉max = sin-1 q/2

l/2

2 2
X l q (3)
2 = 2 − 2

Where,
q = 1/4 of the height of the scissor in lower position
X =the distance between the link/ arm in lower position)

The minimum arm/linkage angle (𝛉min) The minimum linkage angle between the links and
an imaginary horizontal line occurs at the minimum (dead) height.
Considering the lowered position (Figure 5.2)

𝛉min = Opposite/ hypotenuse

𝛉max = sin-1 q/2

l/2

4.4. Design equations for scissor lifter:

For a scissor lifter that has straight, equal-length arms, i.e. the distance from the horizontal
hydrauliearm-attachment point to the scissor-joints is the same as the distance from that scissorjoint
to the top load platform attachment.

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CHAPTER SIX

Proposed 3D Model and 2D Drawing of the components

6.1 Proposed Prototype

The machine consists of a ball screw, ball nut, motor and the lift scissors (X linkages).
Rotation of the ball screw attached to the shaft of motor drives the system. The ball screw
rotates and this drives the main scissor mechanism.
Thus, the rotary motion is converted into reciprocating/ linear motion by using ball screw
which moves the table.

6.2 Design of Components

Fixtures must always be designed with economics in mind; the purpose of these devices is
to reduce costs, time wastage and labor. So they must be designed in such way that the cost
reduction, time usage and the use of man power outweighs the implementing of the fixture.
It is usually better, from an economic standpoint, for a fixture to result in a small cost
reduction for a process in constant use, than for a large cost reduction for process used only
occasionally.
These machines may also be designed for very general or simple uses, These multi-use
fixtures tend to be very simple themselves, often relying on the precision and ingenuity of
the operator, as well as surfaces and components already present in the workshop, to
provide the same benefits of a specially-designed fixture.
In our design the Aerial electric Scissor Lifts comprises of nine components. There is no
concrete design procedure available for designing these components. The main
components of the lift are Base plate, Upper plate, ball screw, nut, links and pins, On the
basis of certain assumptions, the design procedure for each of the components has been
described as follows:

 Design of base plate:

The base plate in a scissor lift only provides proper balance to the structure. Considering
the
size constraints, the dimensions of the base plate are taken as under. Also, it has been found
that not much of the stresses are developed in the base plate. It is responsible for the lift to
handle the total weight of the lift and the weight to be carried.
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 Design of upper plate (Platform):

The upper plate in a scissor lift is used to place the load and transfer it to the links. The
designing of the upper plate is undertaken similar as the base plate. The upper plate has the
similar requirements as the base plate. Also, it has been found that not much of the stresses
are developed in the upper plate as well.

 Design of scissor link:

The scissor link is responsible for the lift structure to move up and down.

 Design of Bolts
The bolt is one of the important elements in the aerial seissor lift, The carries major stress
during static and dynamic conditions. The bolt is used to join two centers of the scissor
links
which forms a fulcrum point for the two-scissor links.

 Design of Ball Screw

They are used to transmit power from motor to Ball Nut.

 Design of Link Bar

It is used to connect Two Scissor Bar.
 Motor
Motor used in this project have a high torque and low RPM .

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Table 3. Detail of Components

S.no. Parameters Measurements

1. Ball Screw Diameter
2. Length of Links
3. Width of Links
4. Height of Links
5. Diameter of Motor Sprocket
6. Diameter of Ball Screw
7. Cross Section of Upper Plate
8. Cross section of Lower Plate

6.4 Drafting and 3D Model

6.4.1 Isometric View

Figure 6.1: Isometric View

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6.4.2 Front View

Figure 6.2: Front View

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6.4.3 Side View

Figure 6.3: Side View

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6.4.4 Assembly Drawing

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6.4.5.1 Scissor link

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6.4.5.2 Ball Screw

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6.4.5.3 Bass Plate

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6.4.5.4 Platform

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6.4.5.5 Ball Nut

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6.4.5.6 Motor

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Software Requirement
We went with SolidWorks 2020 software to craft the 3D designs of our mechanical parts
and assemble our project. This choice allowed us to create simulations as well.

Conclusion
It can be concluded that the mechanical design for the electric scissor lift that we have
aimed was successful. A platform, base plate, scissor arms, wheels, ball screw and nut
make up the system. The design of this components and assembly implies the final outlook
of the design when it is implemented.

Recommendation
This project can be carried out at other project levels. An electric scissor lift can be
achieved with the project itself, which will serve as thereafter for the purpose of business.
This project can be implemented in areas where there is a need of transportation to an
elevated height. Considering the amount of time and labor it saves, the project's long-term
effects are highly significant

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CHAPTER SEVEN

Conclusion and Recommendation

Conclusion

This internship program is designed to introduce real-world job experiences, which we will
be working on after graduation. Starting from finding the hosting company working inside
and observing the ways in which the work flows and the job is done, the internship program
was a great way to let us face the challenges and benefits of being a professional. The
Hawassa industrial park, ZLD plant has the job of electrical, mechanical, and
instrumentation departments. Working inside ZLD plant, we were able to grasp practical
knowledge related to our field of study and to identify most of the operation taken in the
plant to successfully treat the sewage and effluent.
We’ve found the overall experience of the internship a good way of experiencing the
practical way of acquiring and practicing theoretical knowledge.
In general, we conclude that our internship was a huge success and that we gained a lot of
valuable experience. The most important skills we gained from the internship were work
experience in the field of interest, which created a springboard from college life and helped
us improve various aspects such as communication skills, work ethics, teamwork, and
others.

7.1 Limitation
Even though we had an overall good experience despite the intern problems that we faced.
Here is the list of limitations we faced on both sides

7.1.1 Limitations of the University

 The university doesn’t have any linkage to the company, which makes it harder
for students to work.
 We also faced financial difficulty during the internship program since the
required body didn’t make our internship payment on time.
7.1.2 Limitations of ZLD plant
The company doesn’t have necessary spare parts to the industrial machines due to this
there are plenty of machines that are not working.

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7.2.1 Recommendation for the University

As previously stated, this internship program has provided us with numerous benefits,
including the development of social communication skills and the best practical experience
for memorizing what we learned in the previous four years of academic study. Because of
this, as well as the other benefits listed above, we would like to recommend that our school
continue to provide students with this wonderful opportunity.
 Should check whether the advisor is checking he/she is working or not.
 Should allow students to find internship organization by their own which
will enable them to experience most of the tasks closely related to their
field of study.
 Should pay the intern payment of student at the right time.

7.2.2 Recommendation to the Company

 The company should assign additional professionals who help only intern students.

 The company does not have enough workshop materials; the company should full
fill those materials for effective work and desired products.
 A limited budget is allocated to the company as we heard from the employees there.
Due to the scarcity of the budget, there is a limited spare parts. So, more budgets
should be allocated in order to improve the quality of the organization.

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Reference

[1] Hawassa Industrial Park (HIP) - Electrical and mechanical training ppt.

[2] Hawassa Industrial Park (HIP) – Automation and instruments training ppt.

[3] M.C. Şenel, Ş. Üstün. The Design of Scissor Lifting System, Gazi University, Faculty of
Engineering Mechanical Engineering Department, Graduation Thesis, 2009.

[4] Soma Raghavendra, C.; Raghunath Reddy, B.; Tech Student, M. Design and Analysis of an
Aerial Scissor Lift. Int. J. Eng. Sci. Comput. 2017

[5] Y. Aksungur, M.Y. Nayir, E. Güneş. Senior design project: design and analysis of an aerial
working platform, TOBB ETÜ, Ankara, 2012.

[6] T. Hongyou, Z. Ziyi. Design and simulation based on Pro/E for a hydraulic lift platform in
scissors type, Procedia Engineering, Vol.16,

[7] ANSI/SIA A92.6. (2006). Self-Propelled Elevating Aerial Work Platforms. American National
Standards Institute (ANSI), New York, USA.

[8] https://en.wikipedia.org/wiki/Aerial work platform

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Appendix
int state1 = 0;
int state2 = 0;
int push1 = 3;
int push2 = 4;

int enA = 9;
int in1 = 8;
int in2 = 7;

void setup() {
pinMode(push1, INPUT);
pinMode(push2, INPUT);

pinMode(enA, OUTPUT);
pinMode(in1, OUTPUT);
pinMode(in2, OUTPUT);

void loop() {
state1 = digitalRead(push1);
state2 = digitalRead(push2);

if (state1 == HIGH){
analogWrite(enA,255);
digitalWrite(in1, HIGH);
digitalWrite(in2, LOW);
}
else{
digitalWrite(in1, LOW);
digitalWrite(in2, LOW);
}

if (state2 == HIGH){
analogWrite(enA, 255);
digitalWrite(in1, LOW);
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