Main Body of The Report

Debre Tabor University Faculty of Technology // Department of ECE
CHAPTER ONE
1. BACK GROUND OF HAWASSA TEXTILE SHARE COMPANY
Hawassa textile factory was established in November 1989. The textile mill is an integrated
modern factory located in the southern people regional administration capital city was 275km
south of Addis Ababa. It is designed to produces various kinds of woven fabrics from 100% cotton
as well as to finish polyester cotton blended and 100% polyester fabrics. The equipments of
factory are:-an automatic bale pluckier and high speed spinning machine, rapier looms a modern
air conditioning system organized laboratories west water treatment plant are among the latest in
the country and almost all are Italian origin.
The factors land holding is 371,000 square meter of which 31,275 is covered by building and
31,000by an effluent treatment lagoon. The total man power of the factory is 950. The work force
is relatively young with base knowledge to operate and maintain the installed machine and
equipment. The present monthly wage is birr 1.2 million.
Vision
To be export leader of the country by manufacturing 100% cotton products in order to satisfy
customers need.
Mission
To produce 100% pure cotton textile products which can satisfy customer need?
To expend the market share, there by generating profit.
To play vital role in the development of the country economy.
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By. Bereket .B Page 1
1.2 Main Service of the organization

A. Main production and market
Production capacity (annum)
The factory is designed to operate with the following product.

Installed physical capacity (annum)
100% cotton 11.1 million square meters

Poly% cotton 25.0 million square meters
1. Main customers and end users

The opportunity of cotton growth potential and increase in demand for cloth make of cotton in
foreign nations was making huge market demand in the past 20 years. Products for foreign market
were directly delivered by the factory. Its foreign cushe past years were UK, Belgium, Italy,
Switzerland, Sweden and Germany. However, starting from last year all the customers and end
users are local. Off these
Addis Ababa foam
Kangaroo foam
Marias PLC
2. Export Market and Prospect
In the global market textile is the third largest market after tourism and the information industry.
As the textile demand increase with population and per capital consumption, growth and shifting
of the industry to the developing nations with cheap labor cost, Ethiopia textile has huge potential
for export. More over as the country enjoys access to European and American markets exempted
of duty tax and free from all quota restrictions, the textile and clothing industry in the country has
very good potential for export.
3. Opportunities
Cotton growth potential.

Increase in demand for cloth make of cotton in Europe and America.
Huge export market free of quota restriction and duty.
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High domestic economic growth implying increase in disposable income.

Development of infrastructure facilities.
Political stability and liberation of economy.
A. Core Competence to Attract Partners

Majority of the machinerys reasonable new.
Has already developed export market and actively trying to develop others.
Better product quality and design.
Customer service.
Ideal location for expansion program.
Relatively skilled manpower and average age group.
B. Business Environment
General
Since 1993, the country has taken significant measures to revitalize the domestic economy and
create an environment conducive to the proper utilization of the countrys resources. The textile
sub-sector is one of the strategic sectors, which has being given due attention because of its back
and front linkage of its employment opportunity and its potential business environment both in
domestic and export market.
Social Environment
Ethiopia is one of the populous countries in the region and third in Africa with a population size
of 63 million. The annual growth rate is 2.9%.The high population size combined with the growth
of disposable income due to the economic development the country creates high potential demand
of clothing that has a wide gap between current production and demand. Above 50% of the
production is under the age of 20 that creates opportunity for reasonable cheap labor force and at
the same time high consumption of basic needs among which clothing is one.
Technological Environment
Even though the technology in textile is under continuous development to automation and
computer aided design (CAD) the textile industry is still grouped under the labor intensive
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manufacturing. As the standard product or commodities of the industry still do not require highly
flexible equipments, the sector in Ethiopia can easily compete in both export and domestic
markets.
Economic Environment
In wide context, the world economy has being globalized and in order to participate in the market,
the country is making every preparation by due to the continuous reform measures taken. The
economy is growing at an average rate of 7.2% that contributes to growth in the disposable income
of the population. As all the micro economic indicators show this trend is expected to continue in
the coming years. A port from policy adjustments to improve the economy efforts have being made
in developing the infrastructure that is essential for creating new investment opportunities.
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Over all work Sections of the Company
Board of directors
General manager
Plan and Quality Commerce Finance Human and Production

information control Department department administration and
department service dept technical
dept
Purchasing Sales
division division
General Personal Production and
Account administration technical dept
division
Cost and Man power Spinning

budget development division
division division
General Weaving division

service
Knitting
Clinic division
Finishing
Fig 1. Overall organization and structure of the company
division
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Fig2. Over all work

SPINNING
WEAVING FINISHING GARMENT Sections of the
Company
There are different departments performing different and continuous tasks
These are;
Spinning department
Weaving department
Finishing department
Other utilize
Spinning work shop
The spinning department has two productionlinesfor carded and combed yarn with capital of
24,288 spindles, which constitutes 9.4%of the installed national capacity. The installed
machineries include automatic bale pluckier, high speed cards, user auto leveler fitted drawing
formers lap formers, combers, roving frame, ring frames automatic winding machine electronic
assembly winding machine and two-for one twisters except cone winders. Assembly winders and
two-one twisters, which are made by savio, all the rest are manufactured by marzoli.
Weaving workshop
The weaving department consists of two warping machines, one sizing machine 124 somet (sm-
93) papir looms (15%of the installed national capacity of rapier loom), a brushing machine and
inspection machines.
Finishing work shop
The finishing department is capable of finishing 36 million square meter of 100%cotten and
polyester cotton blended fabrics per annum, which are woven in Hawassa and Arbaminch textile
factories. The scoring and bleaching process and the dyeing process use continuous system.
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In addition mercerizing rotary screen-printing and shrink proofing are among some of facilities
available.
Other utilities
The factory is equipped with air conditioning water supply and treatment, steam generation,
diathermic oil heaters waste water treatment and physical and chemical quality control facilities.
Facilities
Electric power is supplied from the national grid of the Ethiopia electric light and Power
Corporation (EEPCO). The total installed capacity is 10,000KVA.
Water is supplied from its own deep well and from city water supply source.
Fuel fired boilers and diathermic oil are the source of steam and heating system.
Well-equipped mechanical and electrical work shop for maintenance service.
Communication services of telephone, telex, fax, p.o.box and email are available.
20 duplex staff canteen and a cafeteria with assembly hall.
Suppliers of main inputs and distance from the factory
s/n Raw material Name of suppliers Distance from the Remark

factory
1 Lint cotton Middle awash area 376km Local
2 Caustic soda Zeway caustic soda 90km/Europe Local/Europe
fact, Europe
3 Sulfuric acid Awash aluminum 257km Local
sulfate
4 Salt MWITE 275km Local
5 Dyestuff and chemical Different Europe Import
Table1.Supplier of main inputs and distances from factory
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Ports and their distance from the factory
s/n Name Distance

1 Bole air port 275km
2 Djibouti 1132km
Table2. Port and their distance from factory
1.3 Objectives of the Internship

General objective
The objective of this program is to expose us to the real job world and to assist us to acquire
problem solving practical skills and knowledge in the area of our study.
To give experimental knowledge under graduate students what real world work looks like
and aware those for their future career as well develop problem solving skill.
Specific objective
To improve practical skill of students,

To introduce students with the real working environment,
To develop ability of organizing and executing Electrical work,
To improve interpersonal communication skill,
To improve leadership skill,
To fill the gap between the theoretical knowledge and real (practical) work,
To understand about work ethics related issue, etc.
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CHAPTER TWO
Project and contribution
2. Waste water treatment Based on PLC
2.1 Abstract of the project
The automation at textile factory wastewater treatment plant (WWTPs) have increased with the
development of technology when treatment requirements. The textile units use a number of dyes,
chemicals and other materials to impart desired quality to the fabrics. This unit generates a
substantial quantity of effluents, the quality of which in most of the cases is unsuitable for further
use and can cause environmental problems, if disposed without proper treatment. The existing
wastewater treatment based on chemicals is so cost and not treated well.
To eradicate the problem we replace the chemical based treatment with by PLC based treatment.
PLC wastewater treatment systems provide reliable low cost and relatively low mentainance
treatment for textile industrial discharges.
The main focus of wastewater treatment plant is to reduce the biological oxidation demand and
chemical oxidation demand in the effluent discharge to natural water.
Wastewater treatment plant are design to function as bacteria farms, where bacteria are feed
oxygen and organic waste .The excess bacteria growth in the system is remove as sludge ,and
this solid waste is then dispose of on land. The project uses PLC s7-300 based on waste water
treatment.
Problem statement
Hawassa textile factory do not have automatic waste water treatment process and these
initiate us to design waste water treatment based on Semitic (PLCs7-300).
The existing waste water treatment in Hawassa textile factory is based on chemical
treatment ; as a result its running cost is so high .Hence we decided to design the waste
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water treatment based biological based treatment .In addition reducing cost is powerful in
providing treated waste water and clean surrounding environment.
2.2 Objective
In this project there are set of objectives intended to attain:
2.2.1 General objective
To design a process for waste water treatment plant using PLCs7-300 and to replace the
existing chemical based treatment by biological treatment for Hawassa textile factory.
2.2.2 Specific objective
To reduce human power.
To give a clear understanding of the basic concept of waste water composition treatment
in the tank, pollutants in waste water, effluent characteristics and its control mechanism
using PLCs7-300.
To protect environmental pollution that by waste water.
To minimize the running cost of the company.
Significance of the project
The design of PLC based on waste water treatment plant controlling system has enormous
advantages for the Hawassa textile share company. This project has great advantage to the
company. Using PLC based automatic controller enables to have reliable system
performance.
Based on these principle the existing waste treatment is as follows .The existing waste
water is based on chemical treatment mechanism and its control system is manually not
automatic. Therefore when we compare the existing waste water treatment with what we
have designed is as follows:-
Table:-3 comparisons of the existing with the modified waste water treatment.
The existing wastewater treatment The modified waste water treatment
Chemical based on waste water treatment PLC based waste water treatment
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It has no heat recovery machine It has heat recovery machine

Manually controlling system Automatic or PLC based control system
It has no waiting tanker It has waiting tanker
2.4 Detailed design and Description of the project

A large volume of waste water treatment is available intermittently from several machine at
different locations in the plant .The feasibility of installing centralized waste water treatment
system should be investigated .The system involves storing waste water in a large tank from where
that stream is pumped to a heat exchanger in order to warm up water.
The overall waste water treatment process:-
Screen Heat Waiting Fine screen Biological

filter recovery tank tank
systeeeee
e
Sludge tank Thickening tank Sedimentation

tank
Environment
Figure 2.1 general process block diagram of waste water treatment.
Some description of the above block diagram:-
Biological tank: it is used to adjust the amount of biological oxidation of the waste water.
Sedimentation tank:- the waste water coming from biological oxidation step is pumped to
the sedimentation tank ,where the separation the liquid part from the sludge takes place by
the means of over flow system.
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Sludge pump:-it is installed in the sedimentation tank, it works by the minimum level
sensor in the sedimentation tank constant and it is controlled by the means of two
pave/work timers its control switch is automatic manual
Controller
Simple closed loop control system:
Controller
output Actuator process
Sensor
Figure2.2 simple closed loop control

Overall control system performance depends on the proper choice of each component of a
control loop. Advanced control strategies are found in WWTPs.
Programmable Logic Controller (PLC S7-300)
The S7-300 is the most often sold SIMATIC controller which makes successful automation
solutions possible. The S7-300 for system solutions with its main importance in production
engineering provides an automation platform which means best solution for your applications.
Permanent innovation makes this automation platform continuously more valuable. It is
characterized by:
TimersinSiemensS7-300
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Siemens S7-300 PLC can be programmed with five types of timers:

S_PULSE Pulse S5 Timer
S_PEXT Extended Pulse S5 Timer
S_ODT On-Delay S5 Timer
S_ODTS Retentive On-Delay S5 Timer
S_OFFDT Off-Delay S5 Timer
Compact design
Many functions are integrated into the CPU (I/O, Technology functions,
PROFIBUS/PROFINET connection)
Maintenance-free thanks to data retentively on Micro Memory Card
Bits 0 through 9 of the timer word contain the time value in binary code. The time value specifies
a number of units. The time updating decrements the time value by one unit at an interval
designated by the time base; Decrementing continues until the time value is equal to zero. The
time range is from 0 to 9,990 seconds. The maximum time value that you can enter is 9,990
seconds, or 2H_46M_30S. These times differ in function but all of them have the block shown in
Figure below in common.
Timer number
Timer type
S Q
TV BI
R BCD
Figure2.3 Timer Block diagram
Where,
S: is the Set (Trigger) signal of the timer.
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TV: is the time value stored in the timer which must be in the form (S5T#tv). The maximum
time value for tv that you can enter is 9,990 seconds, or 2H_46M_30S.
R: is the Reset signal of the timer.
Q: is the output of the timer.
BI: is the current time in binary code.
BCD: is the current time in binary coded decimal code.
Timer number: this can be in the form (T#), where # can be any number in the range (0-
255), since Siemens S7-300 PLC allows the use of 256 timers at max.
Timer type: is one of the 5 timer types mentioned above.
A Programmable Logic Controller, PLC or Programmable Controller is a digital computer used
for automation of electromechanical processes. Unlike general-purpose computers, the PLC is
designed for multiple inputs and output arrangements, extended temperature ranges, immunity to
electrical noise, and resistance to vibration and impact. Programs to control machine operation are
typically stored in battery-backed-up or non-volatile memory. Our Proposed system can be divided
into three main modules- sensing, decision making and implementation. In our project Siemens
S7-300 is used. The S7-300 enables space-saving and modular configurations. In a single-tiered
configuration, S7-300 can support 256 I/O, and in multi-tiered configurations up to 1024 I/O.
singleS7-300 if deployed in an industry can automate and monitor a large number of tanks. PLC
s7-300 components Basically PLC consists of the following elements:
Power supply
Central Processing unit (CPU)
Programming devices
Input and output module
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Figure 2.4 Siemens PLC S7-300
Figure 2.4 Basic components of PLC

In wastewater applications, a Master Logic PLC can be installed on treatment units and networked
with computer. Honeywells ML server interface software allows the Experian HS supervisory
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software to have direct access to all memory locations in the Master Logic PLC for use in operator
displays, trends, reports, etc.
Manual switching
Sensor input PLC OUT PUT
Figure 2.6 General block diagram of the controller and input output interface
The proposed system will control and monitor the liquid level of the tank, temperature of the
wastewater, flow rate, pressure, odor, PH value, color, conductivity and other parameters
continuously and will ensure that a sufficient level of water is maintained. It can be used to prevent
industrial accident by overfilling of any open container, to prevent overfilling of any closed
container thereby creating overpressure condition. The high number of the input output port of the
PLC will enable this single system to control large number of tanks single handedly.
Alarm Systems
Alarm systems should be provided for pump stations. The alarm should be activated in cases of
power failure, sump pump failure, pump failure, unauthorized entry, or any cause of pump station
malfunction, minimum level and maximum level of wastewater, open or close failure in the valves.
Pumping station alarms should be telemetered to a textile facility that is manned 24 hours a day.
If such a facility is not available and a 24-hour holding capacity is not provided, the alarm should
be telemetered to central control room during normal working hours and responsible person(s) in
charge of the lift station during to the home of the off-duty hours.
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CHAPTER THREE
3. INTERNSHIP EXPERIENCE
3.1 Getting and Visiting the Company
When I come to Hawassa Textile factory I have been with training center officers and they where
told as I start at the given area by principles and procedures of the hosting campany.During the
entrance time the companies training center officers also advised us how we manage our time and
use it effectively. Furthermore, they show us overview of company as well as ethics of companies.
3.2 Working Rooms
Hawassa textile Share Company is integrated company which processes 100% of cotton from
spinning up to finishing in their respective section and also garment processing will be done by
some machine followed by kittening. The main work flow is spinning section, weaving section
and substation department.
Spinning Department
Spinning is the first step in the textile. It is the process of changing lint fiber to the weave able or
knittable yarn. Spinning department includes all the activities required to convert cotton in to yarn.
The major raw material for spinning is cotton and polyester.
Contribution of spinning operations makes to the overhead of the company at the planned cost of
low materials consumable & personnel. There are two types of yarn are produced those are long
fiber and short fiber yarn those has different quality which means the one which have long fiber
has high quality & the one which have short fiber has low quality.
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The department contains machines like Mixing Bale Plucker, Metal detector, Six-step cleaner,
Two-Pitter, Auto-Mixer, Horizontal Opener, Carding, Drawing (primary and secondary passage),
Roving, Ring frame, Open-end, Winding, Twister and Doublers.
This Spinning department has five sections and two production lines.
1. The five sections are:
Blower room
Open end
Roving frame
Ring frame
Yarn store
2. The two production lines are:
Open end line
Ring frame line
The spinning department process of flow line order are described in Figure below
Bale
pluckier
Opener Carding
Metal Six step Mixer
detector cleaner
Winding Drawing frame

Ring frame Roving
frame 1st & 2ndstage
Open-end
Yarn store
machine
Fig3.1 Process of Spinning Section
Sections in spinning department

1. Blow room
Blow room is the first process of spinning department where cotton balls/fiber balls are process
for blending, opening and cleaning and to form a required sheet of fibers for subsequent process
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of carding. It contains Bale Pucker, Metal detector, Six-step beater, Two-pitter, Auto-Mixer and
Horizontal
Basic operation involved in the blow room

Opening: - opening is the first operation in the blow room carried out to the stage of flocks
In the blow room and to the stage of individual fiber in the cards.
Cleaning: -this is removal of impurities to make the cotton as clean as possible.
Dust removal: - to remove dusts which are completely enclosed in the flocks.
Mixing or blending: - to achieve the required quality of yarn by blending different kinds
Of cotton in to particular ratio.
Even feed of the material: -to produce a lap of uniform weight per unit length or to
Process the maximum quality which is suitable for carding.
Fig 3.2Bale plucker
2. Carding Machine
Carding operation is done after blow room process. Blow room product is lap or chute, after
carding the output is sliver. Carded sliver feeds to drawing frame for making leveled sliver. This
process is the most important part of spinning. For this reason carding is called the heart of spinning
mill and well carding is half spun. Carding is done for both carded and combed yarns.
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The following are functions of carding: -

Carding is done for the individualization of the fibers
Sliver formation also made by carding machine
Elimination of dust
To facilitate the next drawing frame action
Disentangling of naps
Elimination of short fibers
Fiber parallelization
Sliver formation
Remaining impurities and dust are eliminated
Fig3.3Carding machine
3. Drawing Frame Machine
Drawing frame is third process of spinning department the card sliver has hooked fiber &entangled
fiber those to be paralyzed regularized the strand/sliver (blend, mixing of cotton & polyester in
some ratio) the cotton is to give conformability for wearing & the polyester is to give high strength
The ratio is designed as per desire of the customer &from that the drawn sliver lead to the open
end process or ring line.
There are two types of drawing frame machine in the factory those are
First drawing frame machine
Second drawing frame machine.
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First drawing frame machine is used for doubling (i.e. eight input with one output), elongation
and mixing (cotton with polyester).
Second drawing frame machine is in addition to doing the function of first drawing machine it
has special advantage which is leveling the sliver weight. Equipped with electronic auto leveling
system.
Auto-leveler is an additional device which is meant for correcting the linear density variations in
the delivered sliver by changing either the main draft or break draft of the drafting system,
according to the feed variation.
Fig3.4Drawing machine
4. Roving Frame
Roving is fifth process in carded yarn production & seventh process in camped yarn production of
the spinning department sliver is feed to roving machine &passed through creel & drafting zones.
There are two basic reasons for using roving frame:-
1. The roving sliver is thick and untwisted. Because of its hairiness and fly is created. So draft
is needed to reduce the linear density of sliver. The ring drafting arrangement has no
capable of changing the roving sliver in to yarn.
2. Drawing frame can represent the worst concern able mode of transport and representation
of feed materials to ring spinning frame.
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Fig3.5Roving frame
5. Ring Frame
Ring frame which is the process in carded yarn production eighth process in combed yarn production
roving bobbins are reeled over hangers & roving is passed through guide bars, drafting to draft for
required yarn count & through ring & ring traveler for the formation of yarn which is wound on cops
fitted over roving spindles.
It has unique advantage over spinning technology:
It is universally applied in most of the textile fiber can be spun to required fineness.
The yarn spun from this machine demonstrates excellent quality feature uniform structure
and good strength.
It is easy to operate as compared to other spinning machines
Disadvantages:
More process stage, roving stage exist as extra process compare the other system
The high speed of the traveler damages the fibers capacity of the crop is limited
Energy cost is very high
Low production rate
Objectives of ring frame are to:
Drafting the roving until the required fineness is achieved
Winding the twisted strand (yarn) in a form suitable for storage, transportation andfurther
processing.
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Fig 3.6 Ring frame
6. Winding
Winding which seventh process in carded yarn production & ninth process is in combed yarn
production ring laps are passed through User yarn cleaner & upgrade the yarn marketing or
weaving purpose (for next process).
Fig 3.7 Winding machine
7. Twisting and Doubling

This machine have the same working principle but Twisting use for twisting the yarn in order to get
high strength, and doubling guise fore doubling the yarn.
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Fig3.8 Twisting and doubler machine
8. Open Ending Machine

Open end Machine is a device which is used to drafting fiber masses in to individual fiber. It is
also used for transporting and depositing the fibers to yarn end.It is a means of winding the yarn
in to a package of cone. The open ending machine which described above is shown in the Figure
below
Fig 3.9Open ending Machine
9. Yarn Store
This section is the final section of spinning department and use to store the yarn produces by the
production lines.
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Fig 3.10 Yarn Store
Weaving Department
Weaving is the interlacing of two sets of yarns, i.e. warp and weft yarns at right angle to each
other. In ATSC weaving section includes warping up to inspection machines. The flow chart
described in the Figure below.
Warping Sizing Looming Brushing Inspection
Fig4.11 Process flow of Weaving Section

1. Warping process
This is the process of changing the winding yarn from small size of individual cones to the bigger
cylindrical size roller. This makes suitable for looming and sizing up purpose.
Objectives of warp winding processes are:-
Formation of suitable package for warping
Checking and clearing the yarn from spinning defects
2. Sizing process
It is the process of improving the strength of the yarn by passing through hot solution of starch.
This provides suitable for looming machine.
Objectives of sizing processes are:
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To increase the smoothness of warp yarn by gluing the protrude fibers to the core by
means of size;
To apply a protective coating to the yarn to enable it so as to with stand complex stress
in weaving machines mean while maintaining or enhancing its strength and elasticity;
To improve the weave ability of warp by reducing warp breakages;
3. Looming process
After the required number of warp yarns in the fabrics wound onto the weavers beam, the warp
beam ends are then passed through the drop wires, the heddles of the harness frames and the dent
of the reed. This achieved by drawing in and/or tying in (the choice depending up on whether or
not the new warp is different and from the warp already on the loom).
3. Fabric inspection and rejection
The inspection process might start with 100% inspection; check of every items or random sample
based on statistical calculations as a norm one would expect 100% examination for the first
customer order and there after random sampling based on the quantities to be produced.
Machine Description of Weaving Section
A. Warping Machine
Warping machines have a very simple design, which results in higher speed & consequently in
output increase. This machine is shown in the Figure below.
Fig 3.12 Warping machine
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In warping, the yarns are withdrawn from the single-end yarn packages on the creel & directly
wound on a beam. Warping is used to make smaller intermediate beams called wrappers beams.
These smaller beams are combined later at the sizing stage to produce the weavers beam
A. Textile Sizing Machine

Sizing machine uses chemical for reducing the chances of breaking due to the friction in the
weaving process. The sizing machine improved the process by sizing a warp before putting it into
Fig 3.13Sizing machine
A. Brushing machine
The purpose of this machine is to remove the waste of the cloth and to change the weaving clothe
roller to bunch.
B. Inspection Machine
These machines are designed so that rolls of fabric can be mounted behind the inspection table
under adequate light and wound as the fabric leave the table. These machines are either power
driven or the checker pulls the fabric over the inspection table.
Power Flow Section (Substation in Hawassa Textile S.C)
Hawassa textile share company power section is responsible for supplying continues power supply
to each machines and equipment in all departments especially for the production department. The
power delivered to each machine and equipment should be the necessary value in order to function
properly consequently the machine and equipment can function without getting failure repeatedly,
a few order or less power inputs may cause a series draw back since the machine and equipment
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are pretty sensitive except power taken by the PLCs and power used to initiate the contactors
which is 24v dc each motor uses a three phase 380vac.
AC Mains
The power directly given from Hawassa city substation to the factory is10,000KVA. This amount
of power is distributed to six medium voltages through a ring system (a system in which two lines
come out from the supply distributer, though, when one of the line face fault the other line is used
as supply. The 15kv power from the medium voltage control board passes through step dawn
transformers which convert s the 15kv to 0.4kv or 380v. Which is given to the low voltage control
board? Within the medium voltage control board there are different types of switch like motorized
and earthling and it has also fuse disconnections which are responsible for protect overload.
The medium voltage control board used for two purposes:
as switch during maintenance
as a protection (automatically) during fault
From the low voltage control boards the motors and electrical outlets of different department are
connected.
Power Factor Correction
The ratio of real power to apparent power is called power factor. Inductive loads cause current to
lag behind voltage while capacitive loads causes current to lead voltage. Also the presence of
harmonics current decreases the power factor. The power factor uses the total rms, this including
all harmonics. .
Active power (watt):-is that portion of electrical power that is real, it includes heat loss utility
charge are based on watts.
Apparent power (VA):-is the product of rms voltage and current which relates to the effective
load seen by transformer and current conductors.
Reactive power (VAR):-is the reactive component of the apparent power causes by a phase shift
between a current and voltage in inductors (coils) and capacitors. VARS are present in a
distribution system.
To avoid unnecessary losses, or to meet the acceptable load requirements of the energy supply
utility, power factor correction is often required with induction motors, particularly for large
machines or in installations running many machines.
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The most common power factor correction is by means of added capacitors however, under certain
circumstances the motor controller can also be used for this purpose.In Awassa textile S.C there is
a capacitor bank with a four stage power factor correction capability in which each stage provide
increased power factor correction capability.
Protection and Control Devices
When motors are used, there should be the right controlling system as well as protective devices.
The power flow can be seen below.
3- su pply
Bus bar
Fuse
Contactor
Overload relay / Thermal switch
Motor/ Load
All these are connected in series and have their own rating for different KW motors. Electric
circuit should have the following main parts. These are;
Source of energy The control device

The conductor The load
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List of protective device

1. Electrical Circuit Breakers
A circuit breaker is a protective device that interrupts current flow in a fault condition. It is not
intended for routine use to turn the load on and off.It also a device designed to open and close a
circuit by non-automatic means, and to open the circuit automatically on a predetermined over
current without damage to itself when properly applied within its rating.
Operation
In order to allow power to pass through the breaker, the operating lever is placed in the ON
position. This mechanically closes the contact in the breaker. When current pass through the
device; a magnetic field is developed in the bar. The intensity of this fields focuses through a large
piece of metal at the end of movable arm. When the current existed as predetermined amount, the
magnetic field will pull to the right, releasing the lever and the trip mechanism, allowing the spring
to pull contact open. This will disconnect power to the control circuit. To reset the breaker, it must
first be placed in the OFF position and return to the ON position.
Function
Circuit breakers as switch: - A breaker is a control device, or a controller. A circuit breaker can
control and protect an electrical circuit and people operating the utilization equipment. Circuit
breakers are not designed as replacements for operating controls such as relays, contactors, or
motor starters.
As current levels to be broken:-In current quantity breaker must be able to open overload level
currents.
As over current protection:-Any current in excess of the rated current of the equipment or the
capacity of a conductor. Circuit breakers provide a level of safety against over current conditions
in electrical circuits.
Short Circuits:-A short circuit is an unintended path through which current can flow. Any time
current flows in a path that is not the normal path, we say that the circuit is shorted. A circuit
breaker must be able to respond to a short circuit, which can present a large current flow in a short
period of time.
Generally circuit breakers have the following main advantages:
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Sense the current flowing in the circuit

Measure the current flowing in the circuit
Compare the measured current level to its pre-set trip point
Act within a predetermined time period by opening the circuit as quickly as possible to
Limit the amount of energy that is allowed to flow after the trip point has been reached.
2. Contactors
A contactor is an electrically controlled switch used for switching a power circuit, similar to a
relay except with higher current ratings. A contactor is controlled by a circuit which has a much
lower power level than the switched circuit. Contactors come in many forms with varying
capacities and features Contactors are used to control electric motors, lighting, heating, capacitor
banks, thermal evaporators, and other electrical loads. Contactor does not provide overload
protection. When the coil is energized, the moveable contacts are closed against the stationary
contacts. Figure shows parts of contactor.
Fig 3.14 Contactor parts
Operating principle of contactor
Contactors are designed to be directly connected to high-current load devices. Devices switching
more than 15 amperes or in circuits rated more than a few kilowatts are usually called contactors.
Apart from optional auxiliary low current contacts, contactors are almost exclusively fitted with
normally open contacts. Unlike relays, contactors are designed with features to control and
suppress the arc produced when interrupting heavy motor currents. When current passes through
the electromagnet, a magnetic field is produced; this attracts the moving core of the contactor. The
electromagnet coil draws more current initially, until its inductance increases when the metal core
enters the coil. The moving contact is propelled by the moving core; the force developed by the
electromagnet holds the moving and fixed contacts together. When the contactor coil is de-
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energized, gravity or a spring returns the electromagnet core to its initial position and opens the
contacts.
3. Relays
Relays control current flow in a circuit based on signals obtained from an information source. An
electric signal (Voltage) gets sent to the coil creating a magnetic field, closing the armature, which
closes Normally Open (N.O.) and opens Normally Closed (N.C.) Contacts.
Relays tend to be of lower capacity and are usually designed for both normally closed and normally
open applications.
Operation principle of a Relay
It consists of an operating coil wound around an electromagnet pole piece, a moving armature and
one or more sets of contacts. When a voltage of the correct value is applied across the coil
terminals, the resulting current flow through the coil produces a magnetic field similar to a bar
magnet. The armature is attracted by the magnetic field and so moves a small distance. This
movement operates the contact.
4. Electrical Fuses
In electronics fuse is a type of low resistance resistor that acts as a sacrificial device to provide
over current protection, of either the load or source circuit. It is Over current protection devices
are essential in electrical systems to limit threats to human life and property damage. Figure 2.9
shows a typical fuse parts.
Fig 3.15Fuse parts
Characteristic parameters of fuses are:-Speed, Breaking capacity and Voltage drop.
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Switch: - a switch is a device for making, breaking or changing the connections in an electric
circuit.
Push button: - is a device that provides control of equipment by pressing a button so that it makes
or breaks an electric circuit. When push button is pressed by applying force, the path of electric
current opens or breaks.
Indicator Lamps: - The colors are usually red, green, but other colors are also available. Red
lamps are reserved for safety critical indicators (power is on, the machine is running, an access
panel is open, or that a fault has occurred). Green usually indicates safe conditions (power to the
motor is off, brakes are on, etc.).
Limit switch: - is like a 1 NO +1 NC push buttons. The push button is actuated by hand whereas
the limit switch operated mechanically. The main function of the limit switch is to open or closed
an electric circuit when physical limit of the operation of the controlled device has reached. for
instance, a printing machine stop automatically when paper is fed in a wrong way as the limit
switch installed on its automatically pressed with the pressure of the paper.
In roving frame machine it is used to balance the bobble position move ups and down
Controlling of three phase motors

The controlling system for three phase motors is most of the time in star or delta. However,
sometimes both connections star and delta are used to control a motor at a time. A motor ready for
work can be checked whether right to work or not by using the following methods using digital
multi meter.
Phase to ground should read nothing or should read in Mega ohm.
Phase to phase reading between the three phases should be equal.
Starting and ending terminals of the conductor in the winding should be continuous
In the industry, motor problem is the following is the main point is show below.
Loose connection
Over loading
Over heating
Insulation defect
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To avoid this problem we have used different mechanisms.
This mechanism are:-
Main power checked

Controlling power checked
Fuse checked
Checked motor starting star or delta
Inverters
An inverter is a motor control element that adjusts the speed of an AC induction motor. It does this
by varying the frequency of the AC power to the motor. An inverter also adjusts the voltage to the
motor.
In HTSC inverter is used to control the speed of motors in drawing frame machine. The controlling
is done by using frequency variation of the supplied voltage. For simplicity potentiometer is used
for adjustment of the frequency.
Operation principle of inverter
Most inverters are of the variable voltage, variable frequency design. The converter section uses
semiconductor devices to rectify (convert) the incoming fixed voltage, fixed frequency 3-phase
AC power to DC voltage which is stored in the bus capacitor bank. Then it becomes a steady
source of current for the power devices which are located in what is known as the inverting section.
The inverting section absorbs power from the DC bus capacitor bank, inverts it back to simulated
3-Phase AC sine waves of varying voltage and varying frequency that are typically used to vary
the speed of a 3-phase induction motor.
Rectifier (converter)
A rectifier is an electrical device that converts alternating (AC), which periodically reverses
direction, to direct current (DC), which flows in only one direction. Rectifiers are used in various
devices, including:-DC power supplies, a source of power instead of generating current and High-
voltage direct current power transmission systems.
HTSC use converter at warping machine for controlling the speed of the DC motor. Potentiometer
is used for adjustment the armature voltage which is the main parameter in controlling speed of
DC motor.
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Steam boiler
Steam boiler or simply a 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.
Working Principle of Boiler
The basic working principle of boiler is very simple and easy to understand. The boiler is
essentially a closed vessel inside which water is stored. Fuel in our case wood or coffee husk
briquettes is bunt in a furnace and hot gasses are produced. These hot gasses come in contact with
water vessel where the heat of these hot gases transfer to the water and consequently steam is
produced in the boiler. Then this steam is piped to the turbine of thermal power plant. There are
many different types of boiler utilized for different purposes like running a production unit,
sanitizing some area, sterilizing equipment, to warm up the surroundings etc.
The boiler in the HTSC uses wood or coffee husk briquettes as a fuel and it generate up to 10.33
bar steam and evaporation rate 1500 kg/hr. The steam generated is supplied to the sizing or
weaving preparatory room.
Basic boiler controls

Boilers have to provide steam or hot water whenever heat is needed. A conventional boiler
management control system is often set to provide a continuous hot water or steam supply.Boilers
can be left enabled at no-load conditions, during which time the water temperature will be held at
the designed temperature. Frequent warm-up and shut-down of boilers causes stress buildup.
Boiler manufacturers recommendations provide specific guidelines in this area of operation.
Unless a low-limit for water temperature is used, hot water boiler burners are not controlled to
provide water temperatures based on outdoor temperatures, because the reset schedules require
water temperatures to be supplied below the dew point temperature of the furnace. Some boilers
require incoming water temperatures to be above 140F before going to high-fire.
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The following are three ways to control the output of a commercial boiler:
1. ON/OFF (cycling) control

2. High-fire/low-fire control
3. Modulating control
On/off (cycling) control is most common for small boilers. The burner cycles on and off to
maintain steam pressure or water temperature. Cycling control causes losses in efficiency because
of the cooling (which is necessary for safety) of the fireside surfaces by the natural draft from the
stack during the off, pre-purge and post-purge cycles.This type of controlling is used in HTSC.
Type of sensors used for controlling the operation of the HTSC steam boiler are:-
Water level sensor
Pressure senor
Temperature sensor
A. Water level sensor:-this level sensor is used to measure the level water in the boiler. If the
level is below minimum allowed water level it will send signal for the alarm and for FD Fan
(water feeding motor) and if the water level reaches the required level this sensor send signal
for FD Fan to stop feeding water.
B. Pressure sensor: - the pressure sensor is used to control the pressure level of the steam. The
maximum allowed pressure is up to 8 bar sine the company is not working at its full capacity
it is sated at 5 bar at this time.
C. Temperature sensor: - the temperature sensor used for controlling the level of temperature
in furnace.
3.3 Tasks Performed During the Internship Period

During this third month internship period with the support of our mentors and their assignment
and supervision we were doing different tasks among them some are on board connecting and
testing different motor controlling circuits:
Direct on-line starting method
Forward reverse method
Star delta starting method
Sequential starting method
Dynamic break method
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1. Direct on-line Motor Starting Method
The simplest form of motor starting for the induction motor is the direct online starter consist MCB
or circuit breaker, contactor, and an over load relay for protection. Electromagnetic contactor
which can be opened by the thermal overload relay under fault condition. In this motor starting
mode we made the connection.
Different equipments needed for the direct on line starting method:-
Three phase induction motor
One overload relay
One contactor
the star and stop push buttons
Cable
The procedures that we followed when we constructing the circuit were: first we recognized both
the normal open and normally closed self-hold (auxiliary) of the contactor by measuring their
continuity with a multi meter. Then we checked the fuses and overload relay continuity lastly we
constructed the following circuit as follows:
Fig5. Direct on-line Starting Method

As we see the purpose of this connection mode is run the motor only one direction. So in this motor
starting mode there exists high starting current and high starting torque. In ATSC this type of
starting mechanisms used in roving machine.
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2. Forward reverse motor Starting method
In this kind of motor starting we made the circuit by following same procedure from the above
motor starting mode using the desired materials such as three phase induction motor, two
contactors i.e. one forward mode and one for reverse mode, one overload relay, two start and stop
push buttons, four fuses and cables. Here as we understand the purpose of this motor is to run the
given three phase induction motor either in forward or reverse direction manually by pressing the
start and stop push buttons in both cases such that first the motor run in forward mode after we
pressed the forward push button and then we press the stop push button and after a few minute we
press the reverse start push button and will run in reverse mode.
In HTSC, bell plucker and open-end machines are used this type of starting.
Fig 3.18 Forward Reverse
3. Star-Delta Motor Starting
In this motor starting mode we constructed the circuit following similar procedures from the above
motor starting modes using the materials such as, three phase induction motor, four fuses, three
contactors i.e. one main contractor, one star contactor and one delta contactor , one overload relay,
stop and start push buttons, timer, signal induction lamps and cables . Here we constructed the
circuit as in shown in the following figures with two contactors i.e. both the star and delta
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contactors depend on the main contactor thus when the power is on the main contactors and the
star contactor will be energized and the motor will run in star mode and after a few minute counted
on the timer, the timer make.
The star self-hold normally open and make the delta self-hold normally closed so that the delta
contactor will be energized and the motor run in delta mode. This will reduce high starting current
and torque.
In HTSC, drawing frame machine used this type of starting mechanisms.
Fig 3.19 Control diagram of star delta starter
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Fig 3.20 Power diagram of star delta starting
4. Dynamic break (motor auto-stopping method)
Dynamic braking:Lowers the wear of friction-based braking components, and additionally

regeneration can also lower energy consumption.
Principle of operation:-When braking, the motor fields are connected across either the main the
motor armatures are connected across either the brake grids or supply line. When the stop signal
is applied the DC current from rectifier will create a stationary flux across the rotor this will stop
the motor from rotatin
5. Sequential motor starting method
In industrial processing operation there are cases where machineries should be started one after
another.
Manually
Sequential starting of motors means starting the motors one after the other. This type of control
necessary where second machine before starting must have all the auxiliary equipment. We made
the circuit by following same procedure using the desired materials such as three contactors, three
overload relay, three start and one stop push buttons, and cables.
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Operation: the first motor can be started by pressing push button 1hold on contact 1 will close
and the supply to relay will commence through 1even if switch 1 is released. The second relay gets
supply through contact 1 and third relay get supply through second contact, the third motor can be
started only when 2nd motor is running. The second motor can be started only when first motor
running. The third motor can be stopped by pressing switch 3. When second motor is stopped the
third motor will stop automatically. When first motor is stopped by pressing switch1 all the three
motor will stop.
..
Fig 3.22 Control and Power circuit of 3 stages sequential Control.
3.4 Procedures used to perform different tasks

To execute something first it is better to know about the system you are going to perform. This
makes you confident to work and meet your target. While we perform our task for the first time
we have worked with skilled operator and, chief electrician and additionally to strength the
knowledge about certain subject we read manuals which concern about it. We always ask questions
which are not clear for us and ask the experienced person to show us which we want to know.
Especially working with skillful operators has a great advantage to get more information have
performed whole internship work task with all workers in passion and friendly. Personally
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we think friendship make all things right and help someone to achieve his goal. In short we have
used the following procedures:
Asking people who know

Reading manuals
CHAPTER FOUR
4. BENEFIT THAT GAINED FROM THE INTERNSHIP
Primarily when in third month duration we have got knowledge about different things and also we
developed the theoretical knowledge in to practical knowledge by understanding the science
parallel with it. In general the following skills are some of the skills that we get from stay will be
obtain with duration of the internship program.
4.1 In terms of improving our practical skills

Investigate organizational cultures and work habit of a factory.
Understanding methods of laying raw material in bale store.
Identifying different parameters specification while buying raw material (i.e. cotton)
We have seen different way of raw material mixing in blow room.
Knowing reason of mixing and its advantage.
We have also consolidated knowledge to distinguish and analyzed cotton quality control
before starting the process.
We have also knowledge about working principle and sequence of operation of spinning
and weaving.
Understanding machine maintenance requirement and working procedures.
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Identifying most frequently faced portion and gave immediate response.

Knowing about waste water treatment method.
4.2 In terms of up grading theoretical knowledge

Our theoretical knowledge is up grading with the internship period through;
Safety rule of each operation.
Methods of problem identification and way of response.
Referring different manual of machine.
Working mechanism of different machinery.
Passage of raw material in different section.
Identifying parts of a machine which are mainly need series maintenance in different
department.
4.3 In terms of improving inter personnel communication skills

The internship allow as to meet people who may help us land a job later on and give us the contacts
in the industry. Really, we have seen that without effective communication skills, an employee
cannot succeed in the workplace. If communication can fail or if a message can be understood in
different ways, it will be understood in the way which does the most harm. Generally we have
gained the following interpersonal communication skills .We developed:-
Listening skill,
Forwarding precise messages or instructions,
Providing positive reinforcement to subordinates.
We do not dictate or criticize a person's work in front of others and understanding
about their needs,
We are interested in the people communicating with us,
We Learn from one another interactions by correcting our faults,
Communicate effectively
Demonstrate social and global competence
Allow us to work effectively with others and generally the inter personnel
communication skill used to strengthen employ moral and loyalty.
Improve meeting productivity resolve work place conflicts effectively
Reduce office stress and absenteeism.
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Building positive group spirit.

Improve work place moral with none violent.
4.4 In terms of improving team playing skill

Sharing and being open mind for others idea and preferring working by group is better
than a work done a single.
Ability of problem identification
Selecting the most appropriate method to solve the existing problem.
Generating or forwarding flexible premise to solve the problem arises.
A good decision maker, ability to persuade others etc.
4.5 In terms of leadership skill

Leadership, a critical management skill, is the ability to motivate a group of people toward a
common goal. These items will help us to develop our skills as a leader;
Getting and giving information
Understanding group needs and characteristics
Knowing and understanding group resources
Managing the group
4.6 In terms of understanding about work ethics related issue
As an engineer we have seen that the decisions made will cost too much if they are not
appropriate.
Our work habit must be change always being eager to know something new should be
our habits. We developing the work habit
Give respect and love for our job love our discipline when we have seen on the practical
world and being punctual.
Develop importance of unity in working place
Consolidate the behavior of being diligent.
4.7 In terms of improving entrepreneurship skills

I have also learned from the internship skills .there are many entrepreneurs in the company that
they improve recipe of sizing and chemical finishing with lower cost. Finally they have got reward
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from the company. In general we strongly recommended printing; sizing, preparatory process and
finishing area in textile are some of major area for entrepreneur. Because it needs lower costs and
less energy consumption.
A person being entrepreneur they should have the following characteristics.
Risk taker Self confidence
Creativity Commitment
Innovative Hard work
Advantages of entrepreneurship;
To properly utilize the resource.
Proper utilization of human potential.
To achieve economic development of the region
4.8 Challenges I have faced while performing our work tasks

When the machines were maintained the technicians were not interested to work with
us and at the time when we asked to show us the electrical and mechanical
components.
There are also a communication problem with operators and technicians,
operators run the machine by long time experience and they have no more
knowledge about mechanism of operation of the machine, this makes the way
so difficult to get information about certain machine.
Some manuals are written in Italian language, this makes a challenge to get
information about specific machine.
There are no enough computer accesses in the company.
Most of the company machine working manually.
Transportation problem
Advisor was not coming and giving us some guidance.
4.9 Measurements taken to overcome these challenges

To smoothly contact to all workers.
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To ask the department head about some problems and taking his advice.
By studying different manuals in the library and by asking senior Forman
technicians that work in the factory.
At work we try to approach each worker to make them open to share their knowledge
and skills.
We also try to consider ourselves one of the responsible worker in the factory and
accept all work ethics and rule of the factory
We try to contact the company managers and told them about the transportation and
the allow us to use the company workers bus for only one time per day.
CHAPTER FIVE
5. Conclusion
During this internship I met many kinds of personnel. Some were really voluntary they teach us
things I do not know, welcome us with great spatiality, and take care like I were work there for a
long time. I gained a lot of experience from those people. While staying for four months in the
factory, I have seen different three phase AC motors with their internal parts and, different
machines with their operations and how to maintain them based on their problems using wiring
diagram from the manual when complex problem arises. Also I have got a chance to see most
abundantly applied power and control circuit connection diagram of motors using contactor, relay,
different switches and timer circuit in the factory such as: direct on line, star-delta and forward-
reverse connections dynamic break and sequential motor control .Consequently, I have lucky to
be in Hawassa textile share factory, because I have gathered much knowledge about what I have
studied in class. And there are things that I have to apply what I learn in order to achieve the goal.
Overall I have very happy with our internship period to gain many valuable experiences from this
internship.
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5.1 Recommendation
Recommendation for the company
Concerning on whole internship program I recommended the following in Host Company.
The money that earn for workers are low with respect to others. So the company accepts
the question of the worker to increase the money before the worker left the company.
In the time of production some workers not do well, so supervisors should manage the
activity of workers continuously as well as fulfill his/her responsibility.
Medical facilities are given in small considerations but such facilities should be given in
good way.
There are also problems in workers regarding to respecting of work time or on punctuality.
Therefore, it should be proper.
The company should plant good air conditioning system for worker in order to get
refreshed air during working time. It should help workers to fulfill their responsibilities
effectively.
They should write their vision, mission and values of company in front of entrance, instead
of put document in the training office.
Provide enough manuals for interns including 3D view for the example sometimes they
place formworks in inappropriate area.
They should provide office for interns and pay pocket money.
Recommendation for university
Universities are providing good opportunities for students in this internship program. But I
would like to recommend our University to do the following during the whole academic
session.
The university should have sent the students to different company in order to finish
their internship program timely.
The university should strive more on quality of education by preparing good
facilities like laboratory, library, work shop and others.
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The teaching learning method shall be more practical other than theoretical, for that
to make the students full confidentand good expert in the field of study.
Reference
1. Hawassa textile share company magazine.
2. Internet access.
3. Daily reports from company.
4. Electrical material and electrical machines book.
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Debre Tabor University Faculty of Technology // Department of ECE

1. BACK GROUND OF HAWASSA TEXTILE SHARE COMPANY

1.2 Main Service of the organization

Production capacity (annum)

The factory is designed to operate with the following product.

100% cotton 11.1 million square meters

1. Main customers and end users

Cotton growth potential.

High domestic economic growth implying increase in disposable income.

A. Core Competence to Attract Partners

Over all work Sections of the Company

Plan and Quality Commerce Finance Human and Production

Cost and Man power Spinning

General Weaving division

Fig2. Over all work

Finishing work shop

Suppliers of main inputs and distance from the factory

s/n Raw material Name of suppliers Distance from the Remark

Table1.Supplier of main inputs and distances from factory

Ports and their distance from the factory

s/n Name Distance

Table2. Port and their distance from factory

1.3 Objectives of the Internship

To improve practical skill of students,

2. Waste water treatment Based on PLC

2.1 Abstract of the project

It has no heat recovery machine It has heat recovery machine

2.4 Detailed design and Description of the project

The overall waste water treatment process:-

Screen Heat Waiting Fine screen Biological

Sludge tank Thickening tank Sedimentation

Figure 2.1 general process block diagram of waste water treatment.

Some description of the above block diagram:-

Figure2.2 simple closed loop control

Programmable Logic Controller (PLC S7-300)

Siemens S7-300 PLC can be programmed with five types of timers:

Figure2.3 Timer Block diagram

Figure 2.4 Siemens PLC S7-300

Figure 2.4 Basic components of PLC

Sensor input PLC OUT PUT

3.1 Getting and Visiting the Company

3.2 Working Rooms

Winding Drawing frame

Fig3.1 Process of Spinning Section

Sections in spinning department

Basic operation involved in the blow room

Fig 3.2Bale plucker

The following are functions of carding: -

Fig 3.6 Ring frame

Fig 3.7 Winding machine

7. Twisting and Doubling

Fig3.8 Twisting and doubler machine

8. Open Ending Machine

Fig 3.9Open ending Machine

Fig 3.10 Yarn Store

Warping Sizing Looming Brushing Inspection

Fig4.11 Process flow of Weaving Section

Fig 3.12 Warping machine

A. Textile Sizing Machine

Fig 3.13Sizing machine

Overload relay / Thermal switch

Source of energy The control device

List of protective device