ACKNOWLEDGEMENT

Firstly, we would like to convey our deep sense of gratitude and thanks to our GOD for the help
the completion of the internship practice and the project report on Alameda Textile P.L.C.

Secondly, we would like to express thanks to our academic advisor Mr.GelasseTsadik for his
excellent support, supervision and guidance with out whom we would not have been able to
complete our internship practice report work successfully. Last but not the least, we would like
to convey our love and respect to our parents.our family members and best friend who supported
us and encouraged us to complete our internship report without any obstacles. and also We
would like to say thank to our company members For providing extended our knowledge in
practical skill.

Finally, it is our privilege to acknowledge the help rendered to us for typing the internship
practice by our assistants who spent time with us and helped our in completing the tasks
successfully. We would like to convey our special thanks to the Gebrerfael Dept. ECED, CET,
Aksum University who provided suitable guidelines which greatly helped us as a Researcher and
preparation of Technical Repot to complete our Research work with a professional bent of mind.

Also, it is our duty and moral responsibility to express our respect and thanks to Department of
electrical & computer Engineering & Tech, Aksum University for you supported as enter Nate
access to complete our project.

i
 ABSTRACT
This project Industrial automatic Fire Detection and Alarm Systems With water sprinkler system
based PLC is a reliable circuit that takes over the task of controlling the alarm as well us fire
extinguisher. That is sprinkler water flow in the event of fire accurately. When smoke particles
enter the light beam path, some of the light is scattered and some absorbed, thereby reducing the
light reaching to the Receiver this obscuration exceeds a set value, the Optical Beam Smoke
Detector responds and communicates its status to a Fire Panel. It is responsible for activating
alarm, pumps motor "output" devices such as horns, bells, warning lights, and actuates the
solenoid to supply the water to firing zone in spinning department in textile industry. If the
control panel is receive signal from any zone the water pumping motor will be switched ON. The
water pump motor will be only switched off until all of the optical beam smoke detectors in
different zone are deactivate. And depend on optical beam smoke detectors in different zone the
alarm in different zone will be activate for a time set value. that means if optical beam smoke
detector in zone one is active at the same time the alarm in zone one will be active up to set time.
The PLC does the above job. It receives the signals from the sensors, and this signal is operated
under the control of software which is stored in ROM. PLC continuously monitor the optical
beam smoke detector. When any smoke due to fire pass through the optical beam smoke
detector Receiver's then the IR Rays falling on the receivers are obstructed. This obstruction is
sensed by the PLC.

ii
1 Table of Contents
ACKNOWLEDGEMENT ............................................................................................................................. i
ABSTRACT.................................................................................................................................................. ii
CHAPTER 1 ................................................................................................................................................. 1
1.INTRODUCTION TO HOSTING COMPANY ........................................................................................ 1
1.1.Back ground of the company .............................................................................................................. 2
1.1.Objective ............................................................................................................................................. 3
1.2.Mission of the company ...................................................................................................................... 3
1.3.Vision .................................................................................................................................................. 4
1.4.Main Products & Services of Almeda textile P.L.C .............................................................................. 4
1.5.main customers or the end users of the company ............................................................................. 5
1.7Overall work flow of the company ...................................................................................................... 6
1.8Major departments of Almeda textile P.L.C ........................................................................................ 7
CHAPTER 2 ................................................................................................................................................. 8
2.2.1work flow in this sections ..................................................................................................................... 9
2.3Main duties of yarn store\Spinning department ................................................................................... 9
1.9Work responsibilities and Assignments ............................................................................................. 11
CHAPTER 3 ............................................................................................................................................... 12
INDUSTRIAL AUTOMATIC FIRE DETECTION AND ALARM SYSTEMS WITH WATER SPRINKLER SYSTEM
BASED PLC ................................................................................................................................................... 12
3.1Introduction ........................................................................................................................................ 12
3.2Statement of the problem ................................................................................................................... 12
3.3Objective of this project......................................................................................................................... 13
3.3.1General objective of this project ..................................................................................................... 13
3.3.2Specific objective ............................................................................................................................... 13
3.4Theory (Literature review) ..................................................................................................................... 13
3.4.1Cause of fire ....................................................................................................................................... 14
3.5Methodology ...................................................................................................................................... 15
3.5.1 Block diagram of over all our project ........................................................................................ 15
3.6 Component of fire detection, alarm & water sprinkler system ......................................................... 15
3.6.1Programmable logic control (PLC) ............................................................................................. 16
3.6.2Transistor: ................................................................................................................................... 17

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 3.6.3Optical Beam Smoke Detector (OBSD): .................................................................................... 17
3.6.4Automatic Fire Alarm System Alarm Output Devices ............................................................... 20
3.6.5Power Supply:-............................................................................................................................ 21
3.6.6Solenoid valve:............................................................................................................................ 21
3.6.7 NCTO contact timer ................................................................................................................... 22
3.6.8Relay construction....................................................................................................................... 22
3.6.9Open types of sprinkler system ....................................................................................................... 24
3.7Project flow chart ............................................................................................................................... 25
3.8Result & desiccation .......................................................................................................................... 26
3.9Program of LOGO! Soft Comfort software ....................................................................................... 27
CHAPTER 4 ............................................................................................................................................... 29
CHALLENGES AND BENEFITS IN THE INTERNSHIP ....................................................................... 29
4.1Main challenges we faced in the hosting company ............................................................................ 29
4.2Measures to solve challenges ............................................................................................................. 29
4.3Benefits we gained from the intern ship ............................................................................................ 30
4.3.1Management skills ...................................................................................................................... 30
4.3.2Professional skill ......................................................................................................................... 30
4.3.3Technical skill ............................................................................................................................. 31
4.3.4Communication skills ................................................................................................................. 31
CHAPTER 5 ............................................................................................................................................... 32
CONCLUSION ANDRECOMMENDATION ........................................................................................... 32
5.1CONCLUSION .................................................................................................................................. 32
5.2Recommendation ............................................................................................................................... 33
5.2.1Recommendation to the company ................................................................................................... 33
5.2.2Recommendation to the university: ............................................................................................ 33
4 References ........................................................................................................................................... 34
5 Appendix ............................................................................................................................................. 35

iv
 LIST OF FIGURE
Figure1.1 Background of the company ......................................................................................................... 2
Figure 1.2 Main product of almeda textile P.L.C ......................................................................................... 4
Figure 1.3 Overall work flow of the company .............................................................................................. 6
Figure 2.1 Work flow of spinning department .............................................................................................. 9
Figure 2.2 yarn(output of spinning ............................................................................................................. 10
Figure 2.3 Overall Work responsible & Assignment .................................................................................. 11
Figure 3.1 Block diagram of overall our project ......................................................................................... 15
Figure 3.2 OBSD Circuit block diagram .................................................................................................... 17
Figure 3.3 Coverage / Ceiling Height of OBSD ......................................................................................... 19
Figure 3.4 Automatic Fire Alarm System ................................................................................................... 20
Figure 3.5 Block diagram of a power supply .............................................................................................. 21
Figure3.6 solenoid valve circuit diagram .................................................................................................... 21
Figure 3.7 NCTO Timer ............................................................................................................................. 22
Figure 3.8 circuit diagram of pump motor with relay driver ...................................................................... 23
Figure 3.9 project flow chart ....................................................................................................................... 25

v
 CHAPTER 1
1. INTRODUCTION TO HOSTING COMPANY
This report is written in Almeda textile factory it includes the brief history and back ground of
the company this means how the factory is established and with what type of materials were
began its work and how the raw materials which are brings either from abroad or domestic raw
materials are being changed in to product and what type of steps are used to produce them
additionally we explain how the machines are operate mechanically and electrically in order to
perform the desired task again we describe the working flow all the productive&non
productive/supportive departments include in the factory particularly for a motor wiring
connection and capacitor installation and maintenance which is found in the spinning
department as well as in all department since we have been working in this section therefore
we could describe briefly all the working principles ,working flow /procedure & generally how it
operate related with electrical department & its currently efficiency additionally we can realize
how good we have been in performing our task from the explanation again we include the
measures that we have taken in order to overcome these challenges finally we explain how we
improving our practical skills, upgrade our theoretical knowledge ,improving inter personal
communication skills & the knowledge that we gained in terms of entrepreneurship skill etc.

1
 1.1. Back ground of the company

Figure1.1 Background of the company

Almeda textile factory (ALTEX) is one of the nongovernmental entities that were situated seven
kilo meters from center of Adwa or seventeen kilo meters from center of Axum at main road
Adwa to Axum & 1006kilometer from Addis Ababa & 233 kilometer from Mekele capital of
Tigray region. Almeda Textile PLC (privet limited company) is located amidst the beautiful
mountains. There is an air port capable of handling small plains at Axum near the mills site. A
part from other alternatives the factory is directly linked with Djibouti for import/export
incidentals.

Almeda textile is the biggest textile manufacturing company in the country it has100 million birr
sales volume that is 7o% sales in local market &30% volume in global market. Almeda enjoying
from complete new production lines imported from; Switzerland, Italy, Germany, & Japan that
makes up total investment of 94.22million . Employing expatiates to ensure efficient quality &
low cost production availability of local cotton of top quality & the prevalence of well trained
& highly motivated employees. Favorable site policies & intensified management support.
Almeda is one of companies of the EFFERT (endowment fund for rehabilitation of Tigray) with
an objective to enhance the investment opportunity; the group is ready to cooperate with other
companies & individuals who have interesting in investing in the region. Besides the company
aims at getting acceptable rate of return on its investment for the provision of quality products &
services & for satisfying its customer,

The company has its own management system modern technology to produce high quality
product with low cost & to succeed in the local international marketing effectively in its

2
management system the company have different department to facilitate & perform all activities
that carried out in the company. The department can be divided in to production department &
service giving department. Production departments are department those aimed in producing the
product with good quality & product that has the best value on marketing. Company profile

1.1. Objective
 The company is established to accomplish the following business objectives
 To produce threads yarns and all kinds of cloths from, polyester and cotton and polyester
mix at any rate
 To produce clothing materials for personnel and house hold uses.
 To engage in agricultural activities where becomes necessary for the realization of its
business.
 To engage generally in any other trade necessary or conductive to achievement of its
business

1.2. Mission of the company

The mission statement originates from the <total customer satisfaction> for excellence in the
textile field in Africa in general and Ethiopia in particular besides importing. Training and skills
for the human resource development of the inhabitants so much required.

So generally the mission of the company includes;

To make profit by competing in the global market

To generate foreign exchange by increasing export

To create employment opportunities to the community

To have sustainable production capacity and contribute in the development of the foreign and
country

3
 1.3. Vision
Become a best reference and leading Textile and Garmenting industry and creating a HUB par
excellence in the textile and garment fields in Africa in general & in Ethiopia in particular.

Develop Almeda as a reference for Ethiopia textile and garmenting industry and create the
conditioned that Almeda can become leader in the Ethiopian market in terms of export and local
market sales.Core values:

 Customer satisfaction
 Reliability
 Commitment
 Good governance
 Production program

1.4.Main Products & Services of Almeda textile P.L.C

Figure 1.2 Main product of almeda textile P.L.C

Product is the outcome of a production process supplied to the public at large. It should be
delivered to the society in the required amount quantity and time as well as at reasonable price.
Almeda textile P.L.C. is capable to produce any variety of fabric; however, the product mix
ranges from drill, twill, poplin and sheeting terry towels to heavy duty canvas. On the garment
side, knit fabric of various weighted as well as dyed fabric can be converted to value added
articles for which all the paraphernalia is present at the same location. Lists of products that the
company currently running are:

Home textiles such as bed sheet, pillow case, draw sheet, apron

Health care items such as patient gown, overcoat, scrap suits, trouser & jacket

Work wears such as overall, overcoat, jacket and pant

4
Apparels such as shirt denim trousers and chino trousers

Different kinds of knit wear products such as basic t-shirt, polo, singlet & mock neck

Dyed & printed fabrics

1.5.main customers or the end users of the company

the potential of the company’s production capacity by balancing the demand and supply of the
company. Almeda have an enough potential customers locally and globally these are;

Global customers (experts) such as USA, Sudan, Germany,Italy etc.

Local customers Customer’s are the consumers of one company’s product and these also play an
important role in increasing

National defiance

Federal police

Guna P.L.C Guna: Pillow cover and Bedsheet

Messebo:Cap ,Trouser ,Work jacket ,Over all of long sleeve

Altex oromia police & federal police:Workers uniform , shirt,Worktrouser Local :Cap ,Bib
trouser

QC-supply: Bib trouse, Short sleeve over all

tigray police:trouser , shirt, long sleeve overall

military of national defence :cap, trouser,shirt

beggali: work jacket & work overcoat

Tigray, Afar, Amhara, Oromia, Southern nation’s nationalities & people, Gambella, Harrer
&Benshangulegumz regional state police. These and other is the major customer of Almeda
textile P.L.C. in local and in global market.

5
 1.7 Overall work flow of the company

Figure 1.3 Overall work flow of the company

Raw materials and input to the company Almeda textile P.L.C uses cotton & polyester as raw
material & other inputs for its production. These raw materials are supplied from different areas
(from local or global markets).

Cotton- this is used as raw material for the production of the company’s product. And it can be
supplied from local suppliers. These suppliers are;

 Hiwotsupplier found inDansha

 Middle awash found in awash afar region
 Omovallies, omerfound in addisAbaba

6
  Polyester – this one is also the main required raw material in the company& supplied
from Korea, Turkey and China.

1.8 Major departments of Almeda textile P.L.C

The department can be divided in to production department & service giving department.
Almeda textile P.L.C has six major departments these are;

1.8.1 Production departments

Are department those aimed in producing the product with good quality & product that has the
best value on marketing. These production departments are:-

 Spinning department-in this department the raw material (cotton & polyester)are
converted to useable form of yarn. This department contains different machineries &
flow lines.
 Weaving department-in this department the yarn out putted from spinning is used as
input to this department & converted to fabric form.
 Processing department-in this the fabric out putted from weaving changed to colorized
fabric by using different chemicals.
 Knitting department-this department converts the yarn produced in spinning to smooth
fabric that used to produce T-shirts.
 Dayng department-this department changes the color of the fabric produced in knitting
department.
 Garment department –It is used to the colorized fabrics come from processing & knitting
departments & converted to different types of cloths & other out puts.

7
 CHAPTER 2
OVERALL INTERNSHIP EXPERIENCE
2.1 How we get in to the company
When we arrived in to the company at July 20, 2012 we reported the letter that was received
from industrial linkage office to the company training centre manager as they promised on the
confirmation form they accept and give confidence to us. To participate in all task that relate
with our profession to make the internship program more practically. Then the ATC of training
center assigned a supervisor Mr. Brhane G/giworgs he is the head maintenance of spinning
department. After the introduction of our supervisor we are visit all the production line and
engineering department which was found in the company.

After that we are write our intern ship report in the spinning, engineering, motor re winding
departments more deeply .Whereas the other departments have been written by other our
classmate students.

In Altex there are seven departments but since we were instructed to spent our time in those
departments we are mainly visited those departments, So that, we have been working in spinning
section of the company. But this mean we were not restricted working only at those two
departments we were also working at the power system of the whole company.

8
 2.2 Section of the company we have been working

2.2.1 work flow in this sections

Figure 2.1 Work flow of spinning department

2.3 Main duties of yarn store\Spinning department

In spinning department the first stage is blowing. Blowing is a process of mixing of different
types of cotton which is coming from different place & it has different quality which means the
one which have long fiber has high quality & the one which have short fiber has low quality &
removes 10 percent of the waste through unyflock machine& they have six types of waste it
placed in their own store box then the cotton is lead to Carding machine Carding is a process in
which the material is fed through chute feed of blow room in a sheet form this means the
machine produce a SILVER Sliver is a long material (cotton or polyester) which is coiled in the
CAN with reducing its thickness after that the carded material is going to draw in the pre
drawing & drawing machine respectively 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 & the factory example the T-shirt which they wear footballers/athletics

9
many times it is made of polyester in order to give high strength then from that the drawn sliver
lead to the open end process or ring line the process of ring

Open end spinning machine is the fourth process in carded yarn production it is a short cut
spinning process with great economic consideration the yarn is produced directly from the draw
sliver the sliver pass through opening roller by the help of feed roller this is used for low quality
but optionally or when we need a high quality product we can use lap former & comber
machines respectively Lap former machine is fourth process in combed yarn production & it is a
machine that produces a lap of draw sliver in suitable form for comber 36 NO S of first pass
draw sliver is reeled & passed through drafting roller in a sheet form & makes a lap under
calendar pressure then we lead to comber machine it is fifth process in combed yarn production
which removes short fiber from long fiber & hence upgrade the quality of cotton it is in regard of
effective length, short fiber percentage neaps& dead immature fibers & impurities the comber
function is similar as its name reflects that is combed out the above short coming of cotton &
make cotton grade up then the combed material to drawing machine drawing machine is a
process third process of spinning department the card sliver having entangled fibers & drawing
process make them parallel & regular in weight variation 6 to 8 card sliver having parallel fibers
& less weigh variation two or three passages of drawing are selected according to the required
quality of regularity & blend with manmade fibers

Figure 2.2 yarn(output of spinning

10
1.9 Work responsibilities and Assignments

Figure 2.3 Overall Work responsible & Assignment

11
 CHAPTER 3
INDUSTRIAL AUTOMATIC FIRE DETECTION AND ALARM SYSTEMS
WITH WATER SPRINKLER SYSTEM BASED PLC

3.1 Introduction
a key aspect of fire protection is to identify a developing fire emergency in a timely manner, and
to alert the building's occupants and fire emergency organizations. this is the role of fire
detection and alarm systems. depending on the anticipated fire scenario, building and use type,
number and type of occupants, and criticality of contents and mission, these systems can provide
several main functions. first they provide a means to identify a developing fire through either
manual or automatic methods and second, they alert building occupants to a fire condition and
the need to evacuate. another common function is the transmission of an alarm notification signal
to the fire department or other emergency response organization. they may also shut down
electrical, air handling equipment or special process operations, and they may be used to initiate
automatic suppression systems. this section will describe the basic aspect for most fires, water
represents the ideal extinguishing agent. fire sprinklers utilize water by direct application onto
flames and heat, which causes cooling of the combustion process and prevents ignition of
adjacent combustibles. they are most effective during the fire's initial flame growth stage, while
the fire is relatively easy to control. a properly selected sprinkler will detect the fire's heat,
initiate alarm, and begin suppression within moments after flames appear. in most instances
sprinklers will control fire advancement within a few minutes of their activation, which will in
turn result in significantly less damage than otherwise would happen without sprinklers.

3.2 Statement of the problem

 Manual call point alarm system:- Manual call points, often known as ‘break-glass’ call
points, enable a person who discovers a fire to immediately raise the alarm and warn
other people in the premises of the danger.
 Manual water spray system:- when fire is occurred in any zone of spinning department
enable a person who discovers a fire to immediately raise the pump motor & spray of
water over a fire with in a zone..

12
 3.3 Objective of this project

3.3.1 General objective of this project

 .to ensure continuous reliability of the fire alarm system
 Fire Alarm Systems are used to protect life and propertyEstablish the appropriate level of
protection against fire and explosion hazards+ which are appropriate to the level of
business risk .
 Arrive at consistency in risk classification of similar types of facilities
 Arrive at consistency in equipment Specification for gas/fire detection and fire fighting
equipment
 Focus maintenance and pre-fire planning efforts for the most critical pieces of equipment
 Provide an auditable approach to fire and explosion risk management of individual
facilities, which can be readily adapted when these are modified or when conditions such
as production levels or equipment criticality change

3.3.2 Specific objective

 detecting a fire at an early stage
 alerting and evacuating occupants
 notifying the relevant personnel
 activating auxiliary functions e.g. smoke controls, lift homing etc.
 identifying and guiding fire fighters

3.4 Theory (Literature review)

before attempting to understand fire detection systems and automatic sprinklers, it is beneficial to
possess a basic knowledge of fire development and behavior. with this information, the role and
interaction of these supplemental fire safety systems in the protection process can then be better
realized.

Basically, a fire is a chemical reaction in which a carbon based material (fuel), mixes with
oxygen (usually as a component of air), and is heated to a point where flammable vapors are
produced. These vapors can then come in contact with something that is hot enough to cause

13
vapor ignition, and a resulting fire. In simple terms, something that can burn touches something
that is hot, and a fire is produced.

Cotton is an inflammable material and hence prone to fire. It prone to fire more in blow room
and cards. Any spark generate at these places can not only generate the fire but also the same can
propagate to other machines through cotton conveying system.

3.4.1 Cause of fire

Flammable dusts can initiate fire and explosions in factories and warehouses. Dust clouds can be
formed by the release of powder (e.g. foodstuffs or chemicals). Release can occur by puncturing
containers or in the act of transferring powders.
 Equipment and machinery

Common causes of fire in equipment are:

 allowing ventilation points to become clogged or blocked, causing overheating;

 inadequate cleaning of heat-shrink packaging equipment;
 allowing excessive deposits to build up in fume and dust extraction equipment and
associated ducting in catering environments;
 loose drive belts or lack of lubrication leading to increased friction;
 disabling or interfering with automatic or manual safety features and cut-outs;
 leaking valves, glands or joints allowing oils and other flammable liquids to contaminate
adjacent floors or goods;
 Electrical safety

Electrical equipment is a significant cause of accidental fires in factories and warehouses.

The main causes are:

 overheating cables and equipment, e.g.

 due to overloading circuits, bunched or coiled cables or impaired cooling fans;
 incorrect installation or use of equipment;
 little or no maintenance and testing of equipment;
 damaged or inadequate insulation on cables or wiring;

14
  Smoking

Carelessly discarded cigarettes and other smoking materials are a major cause of fire. A cigarette
can smolders for several hours, especially when surrounded by combustible material.
Many fires are started several hours after the smoking materials have been emptied into waste
bags and left for future disposal.

3.5 Methodology

3.5.1 Block diagram of over all our project

Figure 3.1 Block diagram of overall our project

3.6 Component of fire detection, alarm & water sprinkler

system
In our project we used so many equipment’s these are.

 Control panel based PLC Extinguishing Panels (Control for automatic fire protection
equipment Control equipment.
 Optical beam Smoke Detectors ( Fire Detectors )
 Transistor:

15
  Alarm Bells (Fire Alarm Devices )
 water/Sprinkler(Automatic fire protection equipment Automatic equipment))
 Charger/Battery (Power Supply Equipment Power Equipment
 solenoid valve
 Relay driver circuit
 logo comfort software

3.6.1 Programmable logic control (PLC)

A PLC is a microprocessor-based controller with multiple inputs and outputs. It uses a

programmable memory to store instructions and carry out functions to control machines and
processes.

The PLC performs the logic functions of relays, timers, counters and sequencers. It has the
following advantages:

 Low cost
 Reliability
 Reprogram ability

The purpose of a PLC is to directly replace electromechanical relays as logic elements,

substituting instead a solid-state digital computer with a stored program, able to emulate the
interconnection of many relays to perform certain logical tasks. It is the back bone of the entire
system which gives input to the detector and receives the signal from the detectors. It is
responsible for monitoring the various alarm "input" devices such as automatic detection
components, and then activating alarm "output" devices such as horns, solenoids & contactors,
small motors.

A PLC has many "input" terminals, through which it interprets "high" and "low" logical states
from sensors and switches. It also has many output terminals, through which it outputs "high"
and "low" signals to power lights, and other devices lending themselves to on/off control. In an
effort to make PLCs easy to program, their programming language was designed to resemble
ladder logic diagrams. Thus, an industrial electrician or electrical engineer accustomed to reading

16
ladder logic schematics would feel comfortable programming a PLC to perform the same control
functions.

3.6.2 Transistor:
A transistor is used to switch on the output. This is faster than a relay output but is only suitable
for low power direct current applications.

3.6.3 Optical Beam Smoke Detector (OBSD):

A device that monitors the amount of light transmitted between a light source and a
photosensitive receiver. When smoke particles enter the light beam path, some of the light is
scattered and some absorbed, thereby reducing the light reaching the Receiver. If this
obscuration exceeds a set value, the Optical Beam Smoke Detector responds and communicates
its status to a Fire Panel. The area that an Optical Beam Smoke Detector is considered to
effectively sense smoke. An Optical Beam Smoke Detector (OBSD) comprises a Transmitter
(Tx), a Receiver (Rx) and a Control Unit:

The Transmitter is an infrared light source that generates and projects a modulated
infrared(Invisible) light beam over an area to the Receiver.

The Receiver is a photosensitive sensor that forwards the signal to a Control Unit;

The Control Unit, which can be a separate or integrated unit (depending on the type of Optical

Beam Smoke Detector) analyses the signal information and communicates with the Fire Panel on
the status of the Optical Beam Smoke Detector.

Figure 3.2 OBSD Circuit block diagram

The Optical Beam Smoke Detector (OBSD) works on the principle of light obscuration. The
photosensitive element of the OBSD detects IR light produced by the Transmitter in a normal

17
condition. The Receiver is calibrated to a preset sensitivity level based on a percentage of total
obscuration.

Unlike point-type optical smoke detectors,

OBSDs are generally less sensitive to the color of smoke. Therefore, an Optical Beam Smoke

Detector may be well suited to applications that are unsuitable for point-type optical detectors,
such as applications where the anticipated fire would produce black smoke. OBSDs do require
visible smoke and therefore may not be as sensitive as ionization detectors in some applications.

When the IR beam is obscured by smoke the received signal drops accordingly. This obscuration
could be in a concentrated plume of smoke or in a more diluted yet wider plume, both being
within the protected space and presenting the same level of obscuration.

Note: condensation can be considered as an obscuration phenomenon.

Since the sudden and total obscuration of the light beam is not a typical smoke signature, the

OBSD will see this as a fault condition, not an alarm. This threshold is typically set by the
manufacturer. This minimizes the possibility of an unwanted alarm due to the blockage of the
beam by a solid object, such as a display sign or a ladder, being inadvertently placed in the beam
path.

Very small, slow changes in the obscuration of the light source are also not typical of a smoke
signature. These changes may occur because of environmental conditions such as dust or dirt
accumulation on the OBSD’s optical assemblies or on the reflector surface. Small, slow changes
may also occur due to building movement.

Changes caused by environmental conditions are typically compensated for by an automatic gain
control (AGC).Automatic Gain Control (AGC): The ability of an Optical Beam Smoke Detector
to compensate for light signal degradation due to dust or dirt and/or building movement.

The rate of compensation is limited to ensure that the detector is still sensitive to slow,
smouldering fires. When the OBSD is first turned on and put through its set-up program, it
assumes the light signal level at that time as a reference point for a normal condition.

18
As the quality of the light signal degrades over time, the AGC can compensate for this change.

The rate of compensation is limited to ensure that the OBSD will maintain its set sensitivity and
will also still be sensitive to smouldering or slow burning fires.

When the AGC can no longer compensate for the loss of signal (as with an excessive
accumulation of dust or dirt or building movement) the Optical Beam Smoke Detector will signal
a fault condition, so that maintenance can take place.

With a motorized Optical Beam Smoke Detector, it will automatically realign itself to ensure
optimum alignment following building movement.

3.6.3.1 Coverage / Ceiling Height

Optical Beam Smoke Detectors generally have an operating range of up to 100 meters.
However, the optical concept means that the infrared light beam doesn’t suddenly drop at
100metres, but carries on, fading away progressively.
With the Reflected OBSD, the infrared light beam actually travels up to 100 meters and back the
same distance.
Note: End to End Optical Beam Smoke Detectors can be offered with an extended range up to
120metres
The recommended width of detection either side of the infrared light beam axis is 7.5 meters for
satisfactory detection under flat ceilings: and we must installed from 300mm - 600mm above
Ceiling.

Figure 3.3 Coverage / Ceiling Height of OBSD

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 3.6.4 Automatic Fire Alarm System Alarm Output Devices

Automatic Fire Alarm System: A system of controls, initiating devices and alarm signals in
which some or all of the initiating circuits are activated by automatic devices such as Optical
Beam Smoke Detectors. Upon receiving an alarm notification, the fire alarm control panel must
now tell someone that an emergency is underway. This is the primary function of the alarm
output aspect of a system. Occupant signaling components include various audible and visual
alerting components, and are the primary alarm output devices. Bells are the most common and
familiar alarm sounding device, and are appropriate for most building applications. Horns are
another option, and are especially well suited to areas where a loud signal is needed such as
library stacks, and architecturally sensitive buildings where devices need partial concealment.

Figure 3.4 Automatic Fire Alarm System

We would've had to keep pressing the button for as long as we wanted the bell to sound. (A
momentary switch) The latching instructions let us use momentary switches and program the
PLC so that when we push one the output turns on and when we push another the output turns
off. The output of PLC is used to on /off the switch(made up of transistor) the bell depend on
optical beam smoke detector in different zones in spinning department in Almeda company. A
fire alarm system is intended to enable a fire to be detected at a sufficiently early stage so that
people who are

20
at risk can be made safe either by escaping from the fire, or by the fire much difficulty, an early
alarm should operate before the escape routes becomes smoke-logged to such an extent as will
cause occupants to have difficulty finding their way out of the building.

3.6.5 Power Supply:-

Here we used +12V and +5V dc power supply. The main function of this block is to provide the
required amount of voltage to essential circuits. +12voltage is given. +12V is given to relay
driver. To get the +5V dc power supply we have used here PLC, which provides the +5V dc
regulated power supply.

Figure 3.5 Block diagram of a power supply

3.6.6 Solenoid valve:

a solenoid valve has two main parts: the solenoid and the valve. The solenoid converts
electrical energy into mechanical energy which, in turn, opens or closes the valve
mechanically. A digital output pin of the P.L.C is connected to base of transistor which
controls the current to a normally open SPST relay. When the relay coil is energized it closes
the contacts which allows current from the 12 DC supply to flow through the solenoid .when
the solenoid coil is the valve opens allowing water to flow from the reservoir into the fire
occurrence zones. The source must be available at all times because fire can happen at any
time.

Figure3.6 solenoid valve circuit diagram

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 3.6.7 NCTO contact timer
we have the normally-closed, timed-open (NCTO) contact. This type of contact is normally
closed when the coil is unpowered (de-energized). The contact is opened with the application of
power to the relay coil, but only after the coil has been continuously powered for the specified
amount of time. In other words, the direction of the contact's motion (either to close or to open)
is identical to a regular NC contact, but there is a delay in the opening direction. Because the
delay occurs in the direction of coil energization this type of contact is alternatively known as a
normally-closed, on-delay:

Figure 3.7 NCTO Timer

3.6.8 Relay construction

An electric current through a conductor will produce a magnetic field at right angles to the
direction of electron flow. If that conductor is wrapped into a coil shape, the magnetic field
produced will be oriented along the length of the coil. The greater the current, the greater the
strength of the magnetic field, all other factors being equal:

22
Inductors react against changes in current because of the energy stored in this magnetic field.
When we construct a transformer from two inductor coils around a common iron core, we use
this field to transfer energy from one coil to the other. However, there are simpler and more
direct uses for electromagnetic fields than the applications we've seen with inductors and
transformers. The magnetic field produced by a coil of current-carrying wire can be used to exert
a mechanical force on any magnetic object, just as we can use a permanent magnet to attract
magnetic objects, except that this magnet (formed by the coil) can be turned on or off by
switching the current on or off through the coil. Relays are extremely useful when we have a
need to control a large amount of current and/or voltage with a small electrical signal. The relay
coil which produces the magnetic field may only consume fractions of a watt of power, while the
contacts closed or opened by that magnetic field may be able to conduct hundreds of times that
amount of power to a load. In effect, a relay acts as a binary(on or off)amplifier.

Figure 3.8 circuit diagram of pump motor with relay driver

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In the above schematic, the relay's coil is energized by the low-voltage (12 VDC) source, while
the single-pole, single-throw (SPST) contact interrupts the high-voltage (480 VAC) circuit. It is
quite likely that the current required to energize the relay coil will be hundreds of times less than
the current rating of the contact. Typical relay coil currents are well below 1 amp, while typical
contact ratings for industrial relays are at least 10 amps. relay is connected to PLC through a
driver transistor. The relay requires 12 volts at a current of around 100ma, which cannot be
provided by the PLC. So the driver transistor (switch) is added. The relay is used to operate the
external solenoid forming part of a locking device or for operating any other electrical devices.
Normally the relay remains off. As soon as PLC goes high, the relay operates and releases

3.6.9 Open types of sprinkler system

Open types of sprinkler is a Device that automatically discharge water over a specified area.
. Open sprinklers do not have heat activated element and will discharge water as soon as it is
available to the sprinkler system. Open systems require a separate fire detection system to release
the water into the system piping.

3.6.9.1 Fire fighting systems & benefits of water sprinklers system are the following:
 Immediate identification and control of a developing fire. Sprinkler systems respond at
all times, including periods of low occupancy. Control is generally instantaneous.
 Immediate alert. In conjunction with the building fire alarm system, automatic sprinkler
systems will notify occupants and emergency response personnel of the developing fire.
 Reduced heat and smoke damage. Significantly less heat and smoke will be generated
when the fire is extinguished at an early stage.
 Enhanced life safety. Staff, visitors and fire fighters will be subject to less danger when
fire growth is checked.
 Design flexibility. Egress route and fire/smoke barrier placement becomes less restrictive
since early fire control minimizes demand on these systems. Many fire and building
codes will permit design and operations flexibility based on the presence of a fire
sprinkler system
 Enhanced security. A sprinkler controlled fire can reduce demand on security forces by
minimizing intrusion and theft opportunities

24
  Decreased insurance expenditure. Sprinkler controlled fires are less damaging than fires
in non-sprinkler buildings. Insurance underwriters may offer reduced premiums in
sprinkler protected properties.

These benefits should be considered when deciding on the selection of automatic fire sprinkler
protections of fire detection and alarm systems. It Uses open sprinklers to deliver a large quantity
of water over a specified area in a short period of time.

3.7 Project flow chart

Figure 3.9 project flow chart

LOGO! Software

LOGO! Soft Comfort – stands for sensationally easy and quick configuration.
This allows the creation of ladder and function block diagrams by selecting the
respective functions and their connection via drag & drop.
In addition, the entire switching program can be simulated and tested offline on the PC.
Also possible: an online test in both program displays during operation.

Last but not least, LOGO! Soft Comfort provides professional documentation with all of the
necessary project information such as switching programs, comments, and parameter settings.

Benefits of LOGO! Soft Comfort software

25
Together with the LOGO! Soft Comfort software, configuring of the logic module is simply
intuitive: program generation, project simulation and documentation are accomplished using
drag and drop functionality, allowing maximum ease of operation.

The LOGO! Soft Comfort software does it all – generating and testing control programs,
simulating all functions and of course documentation is sensationally easy with LOGO! Soft
Comfort using drag & drop on your PC. This is how it is done:

3.8 Result & desiccation

If the optical beam smoke detector in any zone is interrupted then PLC will turn on the relay &
water pump motor automatically, but the bell type alarm and deluge valve are switch on depend
on optical beam smoke detector with in a zone.

If the optical beam smoke detector in any zone is not interrupted then PLC will be switch off the
relay & water pump motor automatically. but the bell type alarm and solenoid valve are switch
off depend on optical beam smoke detector with in zones.

The water pump motor, bell type alarm & deluge valve are switched on at the same time if and
on if there is interrupted in all zones in spinning department. but bell type alarm is not
continuously switched on up to a fire in a zone is removed by water it only switched on up to set
value(setting time).otherwise it acts as disturbance.
The water pump motor &solenoid valve are switched off at the same time if and only if there is
no interrupted in all zones in spinning department.

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3.9 Program of LOGO! Soft Comfort software

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28
 CHAPTER 4
CHALLENGES AND BENEFITS IN THE INTERNSHIP

4.1 Main challenges we faced in the hosting company

We have faced so many problems in our staying in the internship time. Some of the difficulties
are:

 `Site language- when we joined in to the project the name of spinning department
material made us confusion.
 Work flow- since our site is too vast one worker (employee) can work in many or more
than one works. This make us confused to separate the workers to communicate with us
or to help us by their profession.
 Lack of computer service
 lack of the pocket money

4.2 Measures to solve challenges

As we mentioned the challenges above, we were faced with a lot of challenges; we had look
alternatives to solve them. To solve these problems or challenges we have taken the following
measures.

Regarding to site language we decide to create a good relationship with the daily workers of the
department. All things are simple to know on process after a time, to know the work task of each
employees we decided to arrange a program that meets with the employee for each then the
problem was solved and they are volunteer (responsible) to accept our program, the challenges
regarding to experience as explained above we have good friend ship with all the workers or
employees, so it helps to build a confidence and to communicate with us freely, at that time we
get a good experience from the employee and from the skilled persons. And also we have
Generally most of the challenges were solved through our effort after hard working.

29
 4.3 Benefits we gained from the intern ship

4.3.1 Management skills

We have gained skills such as: management skill, practical or technical skill, professional skill
and communication skill from the intern ship.

Management skill: during the internship we gained management skills such as;

Establishing process and structure,

Build trust and good relationship between team members

Resolve conflicts, swiftly if they occur, provide support, especially to those team members who
are less secure.

Remain positive and firm in the face of challenges to your leader ship or to the team goal.

Delegate tasks and as far as possible.

Identify the stage of development that our team etc.

4.3.2 Professional skill

We got the key knowledge and skill which make our profession unique involves the following
terms, those are:

 Organization knowledge and information

 Knowledge and information management
 Using and exploiting knowledge and information
 Research skills
 Information governance and compliance
 Collection management and development
 Customer, focus, service, design and marketing

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 4.3.3 Technical skill
During the intern ship time we gained practical skills such as reading industrial manual to
identified when problem occurred ,rewinding squirrel cage induction motor and have been
working both as operator and technician in spinning department of the host.

We capable to install home and industry identified industrial problems and solving them.

4.3.4 Communication skills

It is how well we communicate with someone & how well we behave or carry yourself or simply
which means interpersonal skills are how people relate to one another.

As an illustration, it is generally understood that communicating respect for other people or

professionals within will enable one to reduce conflict & increase participation or assistance in
obtaining information or completing tasks.

Having positive interpersonal skills increase the productivity in the organization since the
number of conflicts is reduced. Informal situation, it allows communication to be easy &
comfortable. People with good interpersonal skills can generally control the feelings that emerge
in difficult situations & respond appropriately, instead of being overwhelmed by emotion.
Confidence of the behavior is also play important role in decision to take risk.

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 CHAPTER 5
CONCLUSION ANDRECOMMENDATION

5.1 CONCLUSION
When we reach at the company the worker accepts as in good manner. The responsible person
makes us to get into sections & gives us a supervisor to lead us.

In the department that we have been working there are different machines at which we have
tried to know the operation & electrical equipment’s of individual machine. We have also
observed the work task of other departments & we have installed manual call point alarm system
together with electrician & our supervisor in spinning department. Manual call points, often
known as ‘break-glass’ call points, enable a person who discovers a fire to immediately raise the
alarm and warn other people in the premises of the danger. but this manual call point is not
preferred for protect life of the workers (employees) .because the person may not be see to fire
because of this reason we are motivated to do automatic fire detection and alarm systems with
water sprinkler system based plc in spinning department. This project is used to protect life of
the workers(employees) & materials in Almeda textile factory by using optical beam smoke
detector sensors installed in the Ceiling Height of spinning department. When smoke particles
enter the light beam path, some of the light is scattered and some absorbed, thereby reducing the
light reaching the Receiver. If this obscuration exceeds a set value, the Optical Beam Smoke
Detector responds and communicates its status to a Fire Panel that is plc to switch on the pump
motor, solenoid valve & alarm device. but the output of PLC. is too minimum so by this voltage
pump motor, solenoid valve as well as bell alarm device are not operated so we must installed
other ac source to these equipment’s by using relay driver circuit. relay is connected to PLC
through a driver transistor. The relay requires 12 volts at a current of around 100ma, which
cannot be provided by the PLC. So the driver transistor (switch) is added. Relays are extremely
useful when we have a need to control a large amount of current and/or voltage with a small
electrical signal. The relay coil which produces the magnetic field may only consume fractions
of a watt of power, while the contacts closed or opened by that magnetic field may be able to
conduct hundreds of times that amount of power to a load. In effect, a relay acts as a binary (on
or off) amplifier. The relay is used to operate the external solenoid forming part of a locking

32
device or for operating any other electrical devices. Normally the relay remains off. As soon as
PLC goes high, the relay operates and releases.

So we get the working principle of each department is interconnected each other. We have also
observed additional works that has been performed out of our department like motor winding
&PLC control mechanisms.

5.2 Recommendation

5.2.1 Recommendation to the company

Almost the control system in almeda textile is relay hardware technology so it should replace
with PLC program as much as possible. the company should help the students by giving pocket
money. The project that we have done in spinning department should apply in all department of
the accompany.

Our project is only applicable in spinning department in Almeda textile PLC. because other
departments such as processing, weaving boiler etc. are uses other sensors & fire fighters such
as fixed temperature sensor& carbon dioxide fire fighter system. If such project is applied on all
department of Almeda textile P.L.C neither life of workers nor materials in Almeda are lose in
second semester final project we will do in all departments in Almeda textile P.L.C. by using
different sensors & different fire fighters. Generally this project is applicable in Almeda textile
PLC protect life of the workers. This project must be checked daily, weekly or Monthly (Check
that power supply, indicator, alarm outputs etc. are operating correctly)otherwise it is not
functional.

5.2.2 Recommendation to the university:

In order to amend or improve students’ practical skill, our university has to create industrial
linkage and it should have a work shop in the hosting company. Advisors must available in the
company to coordinate the students during the internship time, but during our intern ship time no
advisor came in to the hosting company. It should send the students to the known company.

Our project also suitable in our university like in all building & offices to protect the structure as
well as life of the person.

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4 References
Bolton, W (2006). Programmable Logic Controllers 4th ed, North Carolina and Elsevier
Newness.

Hugh, J (2008). Automated manufacturing system with PLC Version 5.1

James, H. (1993). Industrial control electronics, James Humphries, Delmar Cengage

Learning; 4th edition
PLC LOGO Instruction manual Siemens
Halo, L. and Ruling, P. (2005). Application of Centralized PLC Automation Control in
Painting Line of Steel Plant. Proceeding of the 4th Asian Conference on Industrial
Automation and Robotics, Landmark Hotel, Thailand
Birbir, Y. and No gay, H. S. (2008). Design and Implementation of PLC-Based Monitoring
Control System for Three-Phase Induction Motors Fed by PWM Inverter. International
Journal of Systems Applications, Engineering & Development, 2, 128-135
Introduction to electrical engineering text book etc.

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5 Appendix
EEFERT:Endowment fund for rehabilitation of Tigray

PLC: programmable logic controller

Plc: privet limited company

ALTEX: Almeda textile factory

Unifolic: sack the lots of cotton and distribute to

Uniclean: clean the dirt on the cotton.

Unimix: mix, clean and open the cotton.

Uniflex:make the cotton flexible and soft condenser

PT 100: senses change in temperature

Jigger, loop steamer, loop former, cold pad batch:

NCTO ,normally-closed, timed-open contact

DGM, department of general manager

HR , human resource

ATC, Advanced training center

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