Internship Final Report and project work 2012 E.

Declaration

I declare that the internship report is one of the ways of improving the theoretical knowledge into
practical knowledge as well as to upgrading the practical skills, which are gained in the hosting
company. I want to approve that this internship report about wow mineral water factory have
been prepared within myself. I have been working my internship experience in wow natural
mineral water factory from September 15, 2012 to January 15, 2012 under the guidance of
Mr.Amare.A (campus advisor).
Generally, the internship report has the aims of providing concise report about the company’s
product, customers, organization structures, overall production process and the problems which
are found in the company and how to solve these problems, one who wants to read this internship
report, can get the general information of the company.

Name of student: Abebe Haile signature ________date____/____/_____

Name of campus advisor: Mr.Amare.A signature______ _ date____/____/ _

Acknowledgment

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First of all I would like to express I heartfelt gratitude to my almighty God for his unrestricted
power and for making everything possible.
Secondly, I would like to acknowledge the support and encouragement from a number of people
those are all department operators, labor workers, managements in this effort. Many individuals
contribute their knowledge and ideas for the accomplishment of this internship practice final
report , then primarily I would like to express great gratitude to my advisor Mr. Amare.A, for
his great effort and contribution to help me to done my report and gave guidelines on the way
how to write report and design a project. Beside of this he has shown a great enthusiast to give
me the desired knowledge and finally I get a better knowledge from the company.

CHAPTER ONE

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1.1 Background

The yakabdi agro processing facility is newly established in Ethiopia. It was built in 2008 E.C, in
Gurage zone, located at the place of Amora Meda rural area which is 8 km far away from gubrye
town and 20 km from Wolkite University and finally 188km from Addis Ababa. Facility was
built in 2.5 hectare land. Yekabdi Agro processing is established as aprivate local manufacturing
company in Ethiopia by its mother company Tenkir Bekele Plastic shoes manufacturing PLC
with the paid capital of 50 million birr. The company entered in the country’s Fast Moving
Consumer Goods (FMCG) industry through manufacturing and supplying of ‘WOW’ natural
purified bottled water. The company uses new technology which production capacity is 12,000
bottle per hour. These fully automatic technologically advanced machineries enable the purifying
and packing process is 100% free of human contact. This gives the customer and consumer a
confidence that Wow water is pure, clean and contamination free. In the company there are 28
labor and 61 head office in total there are 141 permanent workers. The underground water is at
185m from see level.

1.1.2 Objective of the company

The general objective of wow mineral water is to produce and deliver consistent high quality of
wow mineral water at national markets and entrepreneur for local people.

1.1.3 Vision of the company

The company has a vision to fulfill the customers demand and become the chosen best bottled
water supplier in the country with the manufacturing and supplying of clean, mineral reach and
quenching natural water from the chained mountain of Gurage Zone.

1.1.4 Mission of the company

The Company committed to marking its products to all groups, treating or customers with
respect, sensitivity and fairness.

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Its mission is to be the most excellent facility in Ethiopia, will ongoing or constant to become
better responsiveness to the needs and concerns of customers, employees, partners, and
communities in which serve. This will be accomplished through the development of employees,
an emphasis on cost efficiency, market expansion and profitability. Will expand marketing areas
to both protect and improve positions by placing emphasis on innovations and technological
improvement to keep always ahead competition.
1.1.5 Values

wow mineral water Company is those that are designed to be strictly followed and always
practiced by all members of the corporation. These are values ought to be inherited values which
will always lead the day to day activities of every employee; all managers and management
members of wow have to respect them and use them as contractors, they and their employees
have to inherit these values. To highlight the major ones:
• Loyalty

• Problem solving

• Respecting customers and stake holders

• Capacity building, efficiency and Team work

1.2 Main products and services of the company

Currently the company is producing ‘WOW’ natural purified water with 5 sizes; 5000ml,
2000ml, 1500ml, 1000ml and 500ml. the product are being distributed to maney part of the
country with different sales agent or distributers.

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Fig 1 wow bottled water

1.2.0 water standard of WOW natural mineral water

WOW water mineral content WHO standard mineral content

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1.2.1 Distribution

Currently distribute the brand to market via two different methods. Those are
1. Direct Distribution: there are 6 vans that distribute the water directly to
consumer in Addis Abeba and Wolkite.
2. Indirect Distribution: involved 34 distribution agent that get in to
distribution agreement with the company to supply the water to their
specific distribution territories.
In general the end users of wow natural spring bottle water are the people living in
the:

• Most parts of Gurage zone

• Some parts of Amhara region

• Some parts of Oromia region

• Some parts of Addis Ababa

• Most parts of SNNPR

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• Some parts of Harari and afar regions

1.10 organizational structure of the company

Wow natural mineral water Company has three main categories to precede its work. These are
general manager, quality manager and technical manager. General Manager follows the general
work the quality manager manages production quality and the technical manager manages
technical work.

Plant manager

Production Production Technician Finance Quality control

Human & and food safety Sale
resource store Manager Manager Manager
Supply Manager
Manager Manager
Manager

Production Electrical Quality control Fleet

Production & S.V maintenance and food safety S.V
store S.V
Mechanical
Shift for maintenance
man 1 S.V
General
Shift for man 2 account
S.V
Person General Medical
nel Service service and & Cost budget
safety S.V S.V

Sales Up country Ware

promotion S.V sales S.V house

CHAPTER TWO

2. OVERALL INTERNSHIP EXPERIENCE

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2.1 How did I get into the company

First, I have chosen the hosting company that I could get good practical exposure. I choose Wow
mineral natural water factory, and directly I went to company’s human resource office. I told to
the administration secretary from where and why I came to the company and I gave her my letter
of application. She told the technical manager so accepted my letter happily and record my
names.
In the first work day we welcomed by engineer and technician manager Mr. Efrem and Mr. Markos
respectively, and they give us some orientation about the company.
2.2 Section of the company I have been working in

Currently yakabdi agro processing industry is a growing company and it has five main sections
in order to maximize profit and satisfy customer demands or need. The different sections in the
company are listed as follows:
 Power source section
• Manufacturing section

• Compressor section

• Laboratory section

• Store section
We have been working in different subsections of the company those are used for different
purpose those are:
 Power source
• Sand filtration

• Carbon filtration

• Micro filter

• Nano filter

• Ultra-filtration

• Titanium filtration

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• Ozone disinfection

• Chlorine disinfection

• Ultraviolet disinfection

• Blower machine

• Filler machine

• Printer machine

• Labeling machine

• Packing machine and

 Air compressors are the main machines of the company.

2.2.1 Power source

The company has two power sources which are 33 KVA and 15 KVA and one generator which
standby when the two-power source not working. The 33 KVA power source used for the
machine which need high power but the 15 KVA power source used for machine which need
lower power.
2.2.2 Water filtration

The purposes of filtration are to remove contaminants in the water and to make it safe to drink or
any process that makes water more acceptable for a specific end-use. End-use may be drinking;
industrial water supply, irrigation, river flow maintenance or many other uses including being
safely returned to the environment but in the facility the end-use is only for drinking purpose.
Widely varied techniques are available to remove these constituents in my host company like:

• Sand filtration,

• Carbon filtration,

• Exact filtration

• Ultra-filtration and
• Titanium filtration.

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The choice of these unit operations is depending on the quality of raw water available, the cost of
treatment process and the quality standard expected of the processed water: with capturing particulate
matter, inorganic and organic compounds.

2.2.3 Sand filtration

Sand filters are used as a step in the water treatment process of purification. There are three main
types; rapid (gravity) sand filters, upward flow sand filters and slow sand filters. All three
methods are extensively in the industry used throughout the world. But in wow industry there is
a slow sand filter can produce very high quality water free from pathogens, taste and odour
without the need for chemical aids. Sand filters can, apart from being used in water treatment
plants, be used for water purification in singular households as they use materials which are
available for most people. A raw water tank or reservoir tanker it pulled to sand filter tank by
means of two parallel arranged pumps. Sand filtration is a type of water filtration equipment
which works by providing the particulate (suspended) solids with many opportunities to be
captured on the surface of a sand grain

• Direct collision

• Van deer Waals or London force attraction

• Surface charge attraction

• Diffusion

This sand filter may become clogged with a suspended particle after a period of use; but can be
removed by back wash once per day with high pressurized raw water for 20 minutes.

Figure 2.3.1 sand filtration

2.2.4 Micro filtration

Company which is series arranged termed as 1 and 5 micrometers. Micro filtration is pressure
dependent process which remove dissolved solid and other substance from water to lesser extent

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than nano filtration. Membrane with pore size of 0.1 – 10 micrometers perform a micro
filtration. Microfiltration membrane remove all bacteria.

Figure 2.3.2 exact filtration

2.2.5 Nano filter

Nanofiltration membrane also called direct nanofiltration (dNF), are the next
generation polymer membrane have got better and better over the last 50 years. the
principle of these membranes that they can block all kind micro-pollutant and above
all that easier to clean. This is modern type of filter that uses to regulate the standards
of the water mineral came from the ground that set by the company. And also

2.2.6 Titanium filtration

Titanium filtration is one type of water purification technologies that can able to filter up to
0.0005micrometer pore sizes particles and as its name implies it is embedded with 19 titanium
rods. Since it is found next to ozone disinfection tanker in position; it uses to filter disinfected
micro-organism and the retained particles within water that cannot filtered by previous filtrations
system such as sand and carbon.

2.2.7 Flow chart of filtration

Reservoir Sand Carbon Exact UF Titanium

filter filter filter filtration

2.2.8 Objective of filtration

• To eliminate contaminants from water

• To prevent hardness

• To remove dust particle

• To kill bacteria and another microorganism

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• To check turbidity

• To remove different impurities in the raw water

• To get pure/safe water from hard water

2.2.9 Disinfection

Disinfection is accomplished both by filtering out micro-organism and also by adding disinfected
chemicals. Water is disinfected to kill any pathogens which pass through the filters and to
provide a residual doze of disinfectant to kill or inactivate potentially harmful micro-organisms
in the storage and distribution systems. Possible pathogens include: Viruses, Bacteria, including
Salmonella saps, Cholera, Campylobacter and Shigella, and Protozoa, including Giardia lamblia
and other Cryptosporidium saps. Following the introduction of any chemical disinfectant agent,
the water is usually held in temporary storage –often called a contact tank or clear well to allow
the disinfectant action to complete.
Types of disinfectant:

• Ozone disinfection

• Chlorine disinfection

• Hydrogen peroxide disinfection

• Ultraviolet disinfection

2.2.10 Ozone disinfection

It is obvious that ozone is an unstable molecule which readily gives up one atom of oxygen
providing a powerful oxidizing agent which is toxic to most water borne organisms.
Qualitatively, it is very strong, broad spectrum disinfectant. That is widely used in Europe. It is
an effective method to inactivate harmful bacteria, viruses, Guardia, and protozoa that form
cysts. It also works well against almost at other pathogens. In this company ozone is made by
passing oxygen through electrical discharge. To use ozone as disinfectant, it must be created on-
site and added to water by bubble contact this is occur as water drop from the top gravitationally,
ozone flow upwards in ozone tanker as you see from the following picture.

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Some of the advantages of ozone include the production of fewer dangerous by-products and the
absence of tastes and odor problems (in comparison to chlorine). Another advantage of ozone is
that it leaves no residual disinfectant in the water; means, the bottled water allowed to drink after
24 hours it produced. Ozone has been used in drinking water plants since 1996 where the first industrial
Ozonation plant was built in Nice France.

2.2.11 Ozone generator

Ozone generator is used to manufacture ozone out of the most readily-available

substances on earth oxygen in the air. In fact, ozone has been called Enhanced
oxygen for the simple reason that oxygen can be converted to ozone. In order for
oxygen to form into ozone, oxygen molecules must be pulled apart and reformed.
This takes energy in the form of electrical excitation of oxygen which pulls apart
oxygen molecules. This is occasionally accomplished with high voltage (corona
discharge) ozone generators. Once pulled apart, most revert back to the stable form of
oxygen. However, some of oxygen is converted into ozone in this process. Ozone is
colorless gas with a typically antiseptic smell. Ozone must be treated with respect as
it is a very powerful oxidizing agent. So, the name ozone is derived from the Greek
word ozeim which means to smell.

Figure 2.3.3 ozone disinfection tanker

2.2.12 chlorine disinfection

Chlorine is a strong oxidant that rapidly kills many harmful micro-organisms.

Because chlorine is a toxic gas, it is limited to 0-0.5mg/L for drinking purpose; if not
there is a danger of a release associated with its use. This problem is avoided by the
use of sodium hypochlorite, which is a relatively inexpensive solution used in
household bleach that releases free chlorine when dissolved in water. Chlorine
solutions can be generated on site by electrolyzing common salt solutions. A solid

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form, calcium hypochlorite, releases chlorine on contact with water. The generation
of liquid sodium hypochlorite is both inexpensive and safer than the use of gas or
solid chlorine. All forms of chlorine are widely used, despite their respective
drawbacks. One drawback is that chlorine from any source reacts with natural organic
compounds or ozone in the water to form potentially harmful chemical by-products.
Although chlorine is effective in killing bacteria, it has limited effectiveness against
protozoa that form cysts in water (giardia lamblia and cryptosporidium, both of
which are pathogenic). But, in this factory it use only to clean raw water tank.

2.2.13 Hydrogen peroxide disinfection

Hydrogen peroxide is an effective disinfectant that does not add contaminant ions to
water because it degrades into water &oxygen. This is an advantage in critical
systems such as microelectronics where low-level ionic contamination is concern.
Hydrogen peroxide can also be used on membranes that cannot tolerate chlorine.
Generally, it requires high concentrations to be effective. This type of disinfection is
used in wow natural spring bottling water as disinfectant in cleaning the ultra-filter
unit operation.

2.2.14 Ultraviolent disinfection

Ultraviolet light (UV) is very effective at inactivating cysts, in low turbidity water.
UV light’s disinfection effectiveness decreases as turbidity increases, a result of the
absorption, scattering, and shadowing caused by suspended solids. In my host
company because of it use to disinfect cap the above factor is not emphasized. The
main disadvantage of using UV radiation like ozone treatment, it leaves no residual
disinfectant in the water; therefore, it is sometimes necessary to add a residual
disinfectant after the primary disinfection process. This is often done through the
addition of chloramines, that isn’t strong oxidant. When used in this manner,
chloramines provide an effective residual disinfectant with very few of the negative
effects of chlorination.

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2.2.15 Blower machine

Blower machine is a machine where a melted preform is inflated with a high pressure
to form a desired bottles shape with a help of molder equipment as stretcher extended
to limited length. In
wow natural spring water the blower machine is termed as “RJM6” with six molder
as you see from the following picture and whereas the new one with “RJM14” with
fourteen molder and there working principle similar but the reason that differs from
RJM6 is the only speed for instance: 0.5 liters at RJM6 produces 10000 bottle per
hour where as in new one 0.5 liter produces 24000 bottle per hour and we can see
others one by one with their given speed as follows;
RJM6 whereas RJM14l 1-liter 8000bph, 2 liter 5000-6000bph 1 liter 16000-
18000bph, 2-liter 12000bph. And RJM6 has six sensor on each molder

Figure 2.3.4 blower machine

Before the preform enters into the blower it passes through three steps namely:

Preform Hopper-It is a place where the purchased preform immersed or entered to

make comfortable for blower.
Trim-As preform comes from preform hopper through inclined belt conveyor the
trim arranges the preform to proper order or position.
Feeder-This is used only to feed the arranged preform to blower by reading sensor
alarm.

Also, in blower machine there are four sections termed as:

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Star-In this machine there are two stars that feed preform to oven chain and use to
exhaust inflated bottle from grip out to air conveyor.
Grip-Here there are two grips; grip in, that take the melted preform from oven chain
and provide to molder, and grip out that send the molded bottle to air conveyor
through exhaust star.

Oven-The preform that comes from feeder through star melted in this tool with
300kv electrical charge.
Molder-The melted preform enter into molder through grip in to inflated with high
pressure by extending stretcher into melted preform and cover with a seal to
compressor.

2.2.16 Flow chart in blower machine

Preform Star Grip Oven Molder bottle

Trim
hopper

2.2.17 Filler machine

Filler machine is machine where filtered water is poured into designed bottle as it
rotates with a desired speed. This machine has four sections which drive with single
motor.
Namely:

Rinse- use to rinse the empty bottle that comes from the blower machine.

Stars- use to timing empty bottle& filler nozzles.

Filler nozzles-use to pour filter water into rinsed bottles.

Heading cap-used to capping to filled bottle with a cap.

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2.2.18 Flow diagram of compartment in filler machine

Filtered water
Heading Bottled
Stars Filler
Rinse water
nozzles cap
The capacity of production also measured on the board of filler machine control
which is varying based on the type of bottle produced. For example:
RJM6 RJM14

10000bph-for 0.5-liter 24000bph-for 0.5 liter

8000bph-for 1-liter 18000bph-for 1 liter

7000bph-for 2 liters 12000bph-for 2 liters

However, in this machine there is no material balance is calculated, this adversely

affect the company profit. In this machine we don’t know the inlet and the discharged
water; we know only the flow rate of product which based on type bottle produced.
Here in the absence of this material balance can distort the engineering view and
difficult to predict how much filtered water release from this machine by means of
rinsing bottles; by estimation it is around half of the final product.

Consequently, this removed water indirect causes scarcity of filtered water to produce
continuously. As a result of this, for around two-hour downtime is occurring per day;
especially during a production of two litters bottled water. So, to overcome this
problem it is good if it recycled the discharged water that rinse empty bottle to
filtration system rather than removed as waste. Beside to this it is ensure that the
sustainable use of natural resources.

2.2.19 Printer machine

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Printer machine is a computerized machine where expire date and production time is
printed. This helps the company for two purposes:
1) Production time to give responsibilities for each employer for their product.

2) Expire date to give responsible for the company on its product.

2.2.20 Labeling machine

Labeling machine is a machine use to attach a paper to filled bottles that identify the
content of quality and quantity of filtered water. At this machine there is brasher that
put this paper on specific level and screw conveyor that make convenient order to
labeling.

Figure 2.3.5 labeling machine

2.2.21 Packing machine

Packing machine is use to pack the bottled water and it is the end process of
production in the wow spring water industry. Packaging

2.2.22 Air Compressor

Air compressor is used to produce high pressurized air used for different operation. In
this company they use it for compressed air for pneumatic valves, used to up and
down piston type mechanisms to push a bottle to the filler and to stretch the bottle in
the mold.

2.2.23 Air compressor working principles

Air compressor finally wow natural spring Water Company is classified in to two.

A. High pressure air compressor

B. Low pressure air compressor

In this company there are 14 high pressure types air compressors uses to inflate the
melted preform with high pressure around 40bar in blower machine, which is cannot

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work below 25 bar air pressure. But there are 2 low pressure air compressor type
produces only for 7bar-16bar which is not enough to use in blower machine; so, it
serves for packing machine. Air compressor is used to up and down of stock of the
piston to allow air in, and pressurize the air with in storage.

Figure 2.3.6 high pressure air compressor

2.2.24 Programmable logic controller (PLC)

A programmable logic controller is an industrial digital computer which has been

ruggedized and adapted for the control of manufacturing processes, that require high
reliability control and ease of programming and process. In WOW natural mineral
water factory all machine controlled by PLC and SCADA system. SCADA system is
computer monitoring and control system.

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Fig working principle of PLC

2.2.26 Motor
Electrical motor is an electrical machine that convert electrical energy into mechanical energy.
There are two type of motor i.e. DC and AC motor. WOW natural mineral water factory there are
money motor for different purpose and all the motor are three phase induction motor or
synchronousness motor in which the electric current in the rotor needed to produce torque is
obtained by electromagnetic induction from the magnetic field of the stator winding.

Fig induction motor

2.3 Over all work flow

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Chlorine
disinfection placement

Reservoir Carbon filter Micro filtration Nanofiltratio

Sand filter n
tanker tanker

Packing Labeling Printer Filler Titanium Ozonation Pure

machine filter water

Blower Ozone
machine generator

2.4 Challenge and solutions given during task fulfillment

As a beginner internship student without any work experience there were so many
challenges. We have been faced while performing our work tasks i.e.:
• There was also a challenge to prepare report because there is no
documented file for the company

• Even there was challenge to use the internet because as you know; the
company for the time being haven’t Wi-Fi.
• The workshop was limit

• Service, as you know the company is far away from Gubre town.

2.5 Measurement to solve these challenges

Taken measures to overcome this challenge include:

• The first thing is asking my supervisor whatever we want because

since we assigned with him, we must ask him first but within a great
respect manner and also politely
• Reading different books

• Collecting information from the internet

• Asking the workers who have good knowledge for our question

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• Asking important and necessary information from the workers

• Sharing the work load

• Practice and work hard

• Sharing ideas with each other and with different peoples, create good
awareness for every activity
• Careful observation and writing my tasks to follow up day to day

CHAPTER THREE

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3.0 OVERALL BENEFIT OF THE INTERNSHIP

The internship has so many benefits. It improves an awareness of the theoretical knowledge in to
practical knowledge. A skill refers the ability of using that information and applying in a context.
The four-month internship practice was very good in terms of solving problems, gaining working
knowledge and besides knowing about how to plan for the future. The internship provided the
chance to see how the working world would be like and what challenges would be faced after
graduating in my field of study and thus I have got a great deal of knowledge and experience.
3.1. In terms of developing practical skill
In terms of practical skill, I have seen that learning theoretically is more difficult than leaning
practically, but I realize learning is useful for every work, and that make me understand things
easily. Moreover, the internship improves practical skills which are gained in the workshop
course
as well as theoretical knowledge which is learning in our lesson. But when I start practicing it
was
a little bit difficult and after some time I passed it with the real and joyful.

3.2. Improving theoretical knowledge

When people decide that they truly to learn and master a new skill they need a book that is
decided
to the subject matter with details of materials, illustrations of techniques and explicit patterns to
follow or design source books with examples. This internship has benefit for me to upgrade my
theoretical knowledge. In order to improve my theoretical knowledge, I have referred some
books,
using internet access and other sources. In this internship program, I found much theoretical
knowledge familiar with as before.
For example:
 Sensors
 Diode

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 Solenoid valves
 PLC
 motor
Sensors: - are device to provide information on the presence or absence of an object. One type of
feedback frequently needed by industrial control system is the position of one or more
components
of the operation being controlled.
In this plant, almost all sensors are:
 Photo voltaic sensors
 Pressure sensors
 Temperature sensors
 Security sensors
 Electrical sensors (proximity switch)
Diode: - is a PN-junction semi-conductor device which functions as just like an ordinary switch
or used as a switch. The diode also used to change an Ac source to Dc source.
Example: - When the indicator light needs Dc source, the diode gives Dc source to the indicator
light by changing Ac to Dc.
3.2 In terms of improving interpersonal communication skills

I 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, I have gained the following
interpersonal communication skills I have been developed.
 Forwarding precise messages or instructions,
 Providing positive reinforcement to subordinates.
 Listening skill,
 I do not dictate or criticize a person's work in front of others and understanding
3.4. In terms of team work skill
When we work in team, we forget ourselves and work for the common goal. Each member of the
team to cooperate with the other each one has dependent on the other. The member of the team

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have no self-interest. From this team work the team sprit brines unity, oneness, success, harmony
and cooperation. During my team work the member of the team encourages me to work hard
together, and I close collaboration, mutual understanding and respect for each other. It strives for
the promotion of the cause giving each member of the team full scope to make once contribution
according to one’s talent and ability.
 mutual understanding
 respect for each other
 inspire and motivate team members to do their best
 Work hard together
 Listen the ideas and problems and solving the problems.
 Helping each other
3.3 In terms of improving leadership skills
A leadership skill is a critical management skill which is the ability to motivate a group of people
towards a common goal. Leadership, a critical management skill, is the ability to motivate a
group of people toward a common goal. The leadership skill which I develop during internship
period is by observing senior managers, supervisors and each section of the employers of the
major task which they do and I gained from
them. These items will help me to develop my skills as a leader;
 Getting and giving information.
 Understanding group needs and characteristics.
 Knowing and understanding group resources.
 Managing the group.
3.4 In terms of improving work ethics

Work ethics is a belief that hard work and diligence have amoral benefit and an inherent ability
or value to strengthen character and individual ability. These statements of intended conduct are
expected of every member (permanent members, Daily worker) associate members, contract
members and student members) of WOW mineral water factory.
 Respect moral imperatives of society and human well-being.
 Avoid harm to others.

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 Be honest and trustworthy.

 Respect the privacy of others.
 Achieve the highest quality in the processes and products of our work.
 Know and respect existing law pertaining to our professional work
Generally, the internship training program helps to improve the work ethics, such as honesty,
respect, loyalty, punctuality, accountability and to promote a strong team work.
3.7. In terms of entrepreneurship skill

An entrepreneur is a person who start and build a successful business and an individual who
organizes, manages and operates any enterprise, specifically a business, usually with
considerable initiative and taking on financial risk. There are many skills that entrepreneurs
develop over time, but they are a few skills that every entrepreneur must have before opening
“the door” for business. Successful entrepreneurs have skill which increases productivity of the
organization products. These skills are:
 Self-motivation
 Self confidence
 Ethics and moralities
 Time management
 Sales
 Finance
Generally, this entrepreneurship skill has done practically in the company. So that the internship
program has a great role to improve this entrepreneurship skills.

DESIGN OF PLC BASED AUTOMATIC WATER LEVEL CONTROLLER

ABSTRACT

WOW natural mineral water factory has some problems. This project is done in order to solve
the manual problems of the factory. The water that come from the underground to the tank is
controlled by manual system so, this project intended to solve this manual system to automatic
system using PLC. The project “Automatic water level control with an automatic pump control

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system “is designed to monitor the level of liquid in the tank .The system has an automatic
pumping system attached to it so as to refill the tank once the liquid gets to the lower threshold,
while offing the pump once the liquid gets to the higher threshold. Sustainability of available
water resources in many reasons of the world is known dominant issue. This problem is quietly
related to poor water allocation, inefficient use lack of adequate and integrated water
management. Water is commonly used for agriculture, industry and domestic consumption.
Therefore, efficient use and water monitoring are potential constraint for home or office water
management system. This water level control, controls monitor and maintained the water level
in the that come from the underground and ensures the continuous flow of water around the
clock without the stress of going to switch the pump on or off thereby saving time, energy,
water and prevent the pump from over working besides this, the liquid level control system are
widely used for monitoring of liquid levels in reservoirs. Proper monitoring is needed to ensure
water sustainability is actually being reached with displacement linked to sensing and
automation, such a programmatic approach entails PLC based automated water level sensing
and controlling.

CHAPTER ONE

1. Introduction and Background

1.1 Introduction

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In this Project the Controlling of fluid level tank is crucial mechanism in our day to day activity.
In WOW Factory it is common to observe that plentiful fluid is wasted from the tank and
energy and time also wasted.

The project “Automatic fluid level control with an automatic pump control system “is designed
to monitor the level of liquid in the tank. The system has an automatic pumping system attached
to it so as to refill the tank once the liquid gets to the lower threshold, while offing the pump
once the liquid gets to the higher threshold. Sustainability of available water resources in many
reasons of the of the world is known dominant issue. This problem is quietly related to poor
water allocation, inefficient use lack of adequate and integrated water management. Water is
commonly used for agriculture, industry and domestic consumption. Therefore, efficient use and
water monitoring are potential constraint for home or office water management system. More
over the common method of level control for home appliance is simply to start the feed pump at
a low level and allow it to run until a higher water level is reached in the water tank. In order to
ensure safety in production and quality of products, effectively and timely control of liquid level
is necessarily in the previous industry people control liquid level through a fixed liquid level
switch When liquid level is up to certain height, the switch is automatically closed or
disconnected to control water level. I am controlling the liquid level automatically by using PLC,
sensor, motor and valves. The water level is control using different components like PLC,
sensors, motor and valves. The sensors sense the presence of water and give indication to the
PLC. The PLC produce control signal to drive the motor pump. If there is no water content the
PLC give signal to start the motor and if there is sufficient water in the tank the PLC give signal
to stop the motor. A PLC or programming logic controller is a digital computer used for
automation of the electromechanical process. It is used to convert the previously used relay logic
or wired logic for automation of an industrial process into ladder logic.

1.2 Background

In the past centuries, tanks were filling using manual system, so filling tank were energy
consuming and time consuming. Now we are going to design water level controller that uses
single motor and PLC. In many industrial processes, control of liquid level is required. It was

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reported that emergency shut-downs in the nuclear power plant are caused by poor control of the
steam generator water level. Such shutdowns greatly decrease the plant availability and must be
minimized. The project "automatic water level control system" is designed to monitor the level
of liquid in the tank. The system has an automatic pumping system attached to it so as to refill
the tank once the liquid gets to the lower threshold, while offing the pump once the liquid gets to
the higher threshold. Sustainability of available water resource in many reasons of the word is
now a dominant issue. The water level control system automatically maintains the desired level
of water in series of tanks, when source tank water empty the sensor send signal to the PLC the
alarm is on and the PLC automatically stop the pump. It switches ON the pump when the water
level in the tanks goes below a predetermined minimum set level and switches it OFF as soon as
the water level reaches the predetermined maximum level in the tanks to prevent them from
overflowing, thus maintains the water at five fixed levels. User has the flexibility to decide the
water level set points for the operations of pump. It ensures no overflows there by saving energy
and water. Moreover, the system consumes very little energy for continuous operation.

1.3 Statement of the problem

In WOW natural mineral water factory uses process manual for water pumping. An operator has
to arrive at a particular interval of time and made the motor on for pumping; regardless of the
water level if they are unable to monitor continuously, there will be loss of energy sources for
pumping water as well as loss of natural resources due to overflowing of water from tank. Even
if the automatic water level controller that applied in most industries does not consider the level
of source tank. And also, it is time and energy consuming when we control the pump manually.
The water level controller designed in this project can be used to control water flow. However,
there is no way of knowing whether the source of water, actually has water or not. If no water
source is present, then the submersible pump would start running unnecessarily and overheat
itself. This could be taken care by implementing another sensor.

This problem can be reduced by designing an automatic control system which checks the
condition both top and source water tank and display the present status. The PLC reads the status

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of system using the two sensor (upper and lower sensor) and gives desired output by switching
motor and switch on the alarm. The Automatic Water Pump Controller system monitors the water
levels and controls the pump as necessary to prevent breakdown and maximize water storage
without overfilling of the tank and wasting water, the water level digital control system
automatically maintains the desired level of water in a tank.

1.4 Objectives of the project

1.4.1 General objectives

Design PLC based automatic water level controller

1.4.2 Specific objectives

 To be familiar with PLC for industrial applications.

 To monitor tank over filling
 To prevent an industrial accident by over filling an open container
 To design an automatic water monitoring system
 To develop controller using PLC as programming
 To prevent over Laboure of the pumping machine and prevent it from getting bad
 To incorporate an interactive medium between the end user and the machine
 To avoid wastage of water
 Since the demand of electricity is very high, automatic water level control saves energy
 Implementing the system by simulating with proper software

1.5 Significance of the project

 Automatic water level controller save time

 It will reduce human power.
 There will be no overflow of the tank.

1.6 Scope of the project

 Design and simulate automatic water level controller by using sematic manager software

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 Construction of design for the driver

 Sizing and selection of water pump and discharge
 Selecting sensor and CPU type.

4.8 Justification

Automatic water level monitor came into existence because of human error and inconsistence
that is associated with manually operated water pumping machine. This is because it takes time
for individual who is manually operating the water pump to turn off the pumping machine and
this may cause water spillage and at times the individual might not know that the water level has
drop so low until the tank is completely empty. This was the problem that leads to the
development of the ideal of an automatic water level control.

CHAPTER TWO

2.1 LITERATURE SURVEY

1. Automation of tank level by using PLC and establish of HMI by SCADA by Rishabh das
(2013). He analyzed the level control of single tank and implemented control strategy. From his
paper I get knowledge about PLC automation that can be used in controlling water level in
different tanks. Also came to know the process of interfacing the PLC to the HMI by using
SCADA. Understood input and output components that are required to connect with PLC

2. “Programmable Logic Controller “article by Kelvin Ericson (associate professor of electrical

engineering at university of Missouri) This article gives guidelines about basic knowledge of
PLC and the ladder logic operations

3. “CosminaIlles” in his research paper “Water level control system using PLC and Wireless
Sensors” in 2013 described water level control system using Siemens 24RL PLC and a pump
controlled by electric motor. They have used wireless sensor for level monitoring.

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CHAPTER THREE

3. METHODOLOGY

3.1 INTRODUCTION

There are many methods of designing an automatic fluid level control with switching device but
all this methodology requires human assistance. In this project an Automatic fluid level control
for reserve tank, overhead and underground tank with switching device is designed using
electronics control to refill the water without human intervention the system design was carefully
arranged to refill the water tank any time water get low to a certain level finally the system
automatically shut down the water pump by putting the electric pump off when the tank is full.
The tank is to be filled by a pump. The pump will automatically start when the water level the
overhead tank reaches below the low level and stop when the level reaches high level. Provision
of manual start or stop switch is incorporated which will totally override the automatic system.
The following procedures are used to do this project

First, you need to select an instrument or a system that you wish to control. Automated system
can be a machine or a process and can also be called a process control system. Function of a

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process control system is constantly watched by input devices (sensors) that give signals to a
PLC controller. In response to this, PLC controller sends a signal to external output devices
(operative instruments) that actually control how system functions in an assigned manner (for
simplification it is recommended that you draw a block diagram of operations’ flow)

Secondly, you need to specify all input and output instruments that will be connected to a PLC
controller. Input devices are various switches, sensors and such. Output devices can be
solenoids, electromagnetic valves, motors and relays. Following an identification of all input
and output instruments, corresponding designations are assigned to input and output lines of a
PLC controller.

Third, make a ladder diagram for a program by following the sequence of operations that was
determined in the first step.

Finally, program is entered into the PLC controller memory. When finished with programming,
checkup is done for any existing errors in a program code (using functions for diagnostics) and,
if possible, an entire operation is simulated. Before this system is started, you need to check once
again whether all input and output instruments are connected to correct inputs or outputs. By
bringing supply in, system starts working.

3.2 System diagram

Power RRRRRRR

Up sensor

Relay Pump
PLC

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Down sensor

Alarm

Fig block diagram of the system

3.3 System component

3.3.1 Conductivity Level sensors

Conductivity level sensor is a type of liquid level sensor which uses prob to detect the level of
water. When the water reaches the specified position, the sensor tripping a relay contact switch or
transmitting solid state relay switch output when maximum and minimum level has been
reached. The liquid level sensor output can then be utilized to open the valve and the alarm will
be activated or switch on the pump. in this project the water level sensed at two position at upper
and lower position. At this position the water level sensed and send signal to the PLC to take an
action and the alarm will be activated when water is sensed by upper sensor.

3.3.1.1 advantage of conductivity sensor

 Inexpensive, low cost.
 Multiple switch point can be incorporated into one device.
 Simple mechanical construction.
 High temperature fluid compatibility.

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Fig conductive level sensor

3.3.2 Relay

Relays control current flow in a circuit based on signals obtained from an information source. A
relay is the device that open or closes the contacts to cause the operation of the other electric
control. It detects the intolerable or undesirable condition with an assigned area and gives the
commands to the circuit breaker to disconnect the affected area. Thus, protects the system from
damage.

3.3.3 Operating principle of relay

It works on the principle of an electromagnetic attraction. This magnetic field

moves the relay armature for opening or closing the connections.

Fig relay

3.3.4 Start push button

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It is a normally open switch which is used to start the control system.

6.3.4 Stop push button

It is a normally closed switch which used to stop the control system.

3.3.5 Solenoid valve

Solenoid valve is an electrically actuated on/off valve. The solenoid part of the valve is always
in one of two possible states, it’s either energized or de-energized.

3.3.6 Breaker and fuse

breaker is a switching device which can be operated manually as well as

automatically for controlling and protection of electrical power system respectively, whereas a

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.

3.3.7 Programmable Logic Controller (PLC)

Programmable logic controllers, also called programmable controllers or PLCs, are solid-state members
of the computer family, using integrated circuits instead of electromechanical devices to implement
control functions. They are capable of storing instructions, such as sequencing, timing, counting,
arithmetic, data manipulation, and communication, to control industrial machines and processes.

Programmable logic controllers’ function by interpreting data coming through their inputs and

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depending upon their state, turning on/off their outputs. They are programmable via software
interfaced standard computer interfaces, proprietary languages and network options. PLCs

function using relay ladder logic programming. Ladder logic allows programmable logic
controllers to perform any command within the loop at any time.

1. Detect incoming signals

2. Process the signal

3. Generate outputs to control various devices; it achieves machine control as a result of;

a. Program written in to its memory

b. The power of its CPU

During its operation, the CPU completes three processes: (1) it reads, or accepts, the input data
from the field devices via the input interfaces, (2) it executes, or performs, the control program
stored in the memory system, and (3) it writes, or updates, the output devices via the output
interfaces. This process of sequentially reading the inputs, executing the program in memory, and
updating the outputs is known as scanning. Figure below illustrates a graphic representation of a
scan.

fig Illustration of a scan.

3.3.7 Tanks

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The thanks that we used for this specific project are different in size and are connected in a
cascaded or interacting way so that they filled water at the same time. There are four tanks in
WOW natural mineral water factory they are all 25000 liters. The sensor is connected to the first
tank.

3.3.8 Power supply

The automatic water level controlling system has three major parts; level sensing
part, control section and the output section. 230v from the mains supply is step
down by the transformer to 24v and is fed to the PLC. Line voltage is step down
with transformer, rectified to convert it to dc, filtered with Regulator
capacitor. This DC
voltage is used to power the rest of the PLC and component

AC DC
Transformer Rectifier Filter

Fig Block diagram of regulated power supply system

3.4 Flow chart for software simulation

Sensor 1 and 2
detect

No
Low High

Level=1 Level=1

Yes

Valve V1 Valve V2
off on
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Tank

CHAPTER FOUR

RESULT AND DISCUSSION

4.1 Software simulation and discussion

In this project design, the components we have used are sematic manager step 7 PLC, relays,
conductivity sensor and alarm and battery source. In this section those components are
interconnected to show the procedure and method of the real design in sematic manager step 7
PLC. These components are connected and exhibits as they are connected practically. The PLC
drown by using ladder diagram. First the normally open start push button in energized to start the
PLC. There are two conductivity sensor which sense the high level and the low level of the water
tank. When the level sensor senses and the PLC take signal to take an action. When the low-level
sensor is senses the water level or active the PLC start the motor pump and valve V1 is open
secondly when the high-level sensor senses PLC turn off the motor pump and valve V2 open.

 Energize the normally open contactor to start.

 Low level sensor on Pump start and valve V1 on.
 High level sensor on Pump off and valve V2 and alarm on.

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4.2 Ladder diagram

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Table 1.1 Different Result of the System

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Input Output
Sensor 1 Sensor 2 Motor Valve Valve Alarm

(Low) (High) pump V1 V2

1 0 1 1 0 0
0 1 0 0 1 1
0 0 1 1 0 0

4.2 Simulation Result

The aforementioned control design illustrated by the system’s truth table was
simulated using the design parameters described in the previous Chapter (The
Methodology). The control parameters were integrated into one common electronic
circuit design to function as one whole controlling circuit for the entire control
parameter.

4.2.1 Start and Stop pushbutton

The normally open contactor is the main switch of the system all system to get energy the main
switch must be energized.

Fig start and stop PB

4.2.2 Motor pump and Valve V1 on

When the start push button start the pump and the valve V1 is on so that the tank begin to fill.

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4.2.3 When high level sensor active

When the up sensor senses the pump and valve 1 will be off and valve 2 and alarm on.

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4.2.4 When low level sensor active

When the low-level sensor is active and send signal to the PLC, the motor pump will

automatically start to fill the tank.

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4.2 Discussion

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During the course of designing this system there were series of problems encountered which

came on the way of achieving the desired goals of this project. I face a problem while we

designing the programing part especially writing a program on the PLC is a big difficulty

because I am not familiar with the software. Another problem I faced when I doing this

project is shortage of time this is due to time management. Also, I faced internet connection

problem because of this I can’t done what is done at that time.

CHAPTER FIVE

5. CONCLUSION AND RECOMMENDATION

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5.1 Conclusion

This project is specifically designed for the transfer of accurate amount of water desired in any
process or system that involves the measurement of a certain amount of water. The adaptability
in WOW mineral water industry is due to its automatic process. It is more probable that this
project is easy to use and very low cost. In today’s world industries can only grow by making
themselves advance in technology and by upgrading their machineries and plants. I have
proposed an idea of making an automatic water level plant which is normally manual in WOW
natural mineral water industry.

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