INTERNSHIPE REPORT ON AMHARA PIPE FACTORY

CHAPTER ONE

1. Background of Amhara pipe factory

1.1 Brief History (Introduction)

Amhara Pipe Factory PLC (APF) is the biggest among the factories that produce plastic products
in Ethiopia since 2003 E.C. The factory is especially manufacturing and supplying products that
will be used in the projects related with water sector development and construction sectors
according to international standards.

APF is manufacturing two broad categories of products such that Pipes and Plastic sheets. Under
the category of Pipes, .APF manufactures UPVC pipes, HDPE pipes, Casing/Screen pipes and
Flexible hoses. And under the second category, it manufactures geomebrane sheets and
greenhouse film/sheet. APF is a factory awarded with ISO 9001 :2015 quality management
system certificates.

Vision

To become one of the top five plastic industries in East Africa by 2025.

Mission

To produce and supply highest quality products that satisfy Customers needs by optimizing
research and strict quality assurance in all aspect of productionalong side of creating job
opportunities and professionalism in the field.

Values

 Satisfying customers
 Loyal to pay tax,
 Optimizing profit,
 Owning culture of group effort/work.

Main Products

 UPVC Pipes

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 HDPE Pipes
 Screen and Casing Pipes
 Flexible Hose
 Geomembrane Sheet
 GreenHouse Film

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CHAPTER TWO

2. OVERALL INTERNSHIP EXCPERIANCE

2.1 Objectives of the Internship

In our internship program comprises for general and specific objectives. There are;

2.1.1 General objective

The main objective of the internship was to gain an experienced practical knowledge in different
electrical equipment’s and control automation systems by inter-relating with the theoretical
knowledge and to upgrade our technology. Internships will provide us the opportunity to test
their interest in a particular career before permanent commitments are made.

2.1.2 Specific objectives

 To gain a better understanding of the design, structure and information system of an

industrial organization.
 To develop an understanding of an organization's various management and technical
skills, the communications techniques and the decision-making processes.
 To apply the theoretical knowledge (theory, skill development, professionalism) to
the working world.
 To be familiar with different electrical instruments, their application in the real world,
and their control system design and installation to achieve our goals.

2.2 Production Process of Amhara pipe Factory

2.2.1 Mixing: It is a process of mixing raw materials used in the production of PVC. This
machine mixes PVC resign poweder, PVC stabilizer poweder, calcium carbonate poweder,
Titanium dioxide powder, carbon black solid. In order to mix the raw material 120 degree
Celsius is required, it achieved by friction heat. After reaching the required temperature, the
blends automatically

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Figure1. 3 Mixer Machine View

2.2.2 Hopper: hopper is an intermediate storage which sac the blend from cooling
chamber by the help of a small induction motor called sac motor then, feed the blend to
extruder by the help of feed motor. Before the blend reaches the extruder, temporarily
stored in the hopper thus, the feed motor feed into extruder.

2.2.3 Extruder: The extruder has temperature controlled zoned barrel in which rotate
precious screws which is governed by main dc motor. The performance requirement of the
extruder is being successfully met the desired out puts are being attained, with adequate
resin melting and melt homogeneity at a constant discharge pressure and melting
temperature. The dry blend is metered into the barrel and screws which then convert the
dry blend into the required melt state by heat, pressure and shear. In the extruder the
thermocouples are connected in order to sense the current temperature of the mixture and it
would be visible in controlled drums. In the extruder, fans are used to cool the
temperature when it is above the set value and the contactor becomes open. When the
temperature is below the set value the contactor closed and heat supplied into the mixture.

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Figure1. 4 Extruder Machine

2.2.4 Die and Mandrel: The die shaped the extrude malt according to the size of the pipe and
flow characteristics of the malt stream. Dies are used to molding purpose of melted raw materials
and give a definite shape of pipes. Dies adjust the external diameter of the pipe, but mandrel is
used to adjust the internal diameter of the pipe. It takes on a variety of shapes and have
adjustable openings. In case of filament extrusion, and others, multiple duplicate die patterns to
extrude many strands in parallel can be found on a single die. In this part the die uses electrical
heater and thermocouple with temperature controller in order to control the temperature of the
die. Dies are designed to compensate for effects of shrinkage when a melt solidifies.

2.2.5 Bath (cooling): Bath is used to harden the exterior layer of the PVC and hold the pipe
diameter during final cooling in the controlled water cooling chambers. And it contains water
pump which is used to pump cool water and vacuum pump which is used to sac the pressure
around the pipe. It is a part of processing system that is used to cool the pipe by spraying water
when the pipe that comes from the vacuum tank that is not cooled. The purpose of cooling the
pipe by water is nothing but it is used to protect them from bending and to gain definite or
appropriate shape of the pipe.

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Figure1. 5 Cooling Tank

2.2.6 Vacuum Tank: It is a stereotype water tank system which provided with a vacuum for
shaping and cooling of the pipes in the vacuum system and water circulating system, stainless
steel tank, circulating water spray cooling, vacuum shaping water tank is provided with a mobile
device, and moving left and right with regulating manual device

Figure1. 6 Vacuum Tank

2.2.7 Haul off: A machine used to pull the pipe at constant speed but, the pulling speed
is appropriate with feed speed. Thus, the two speeds have to be synchronized. It is

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basically work with forward reverse controlling methods. Speed control is very important
when this equipment is used because the speed at which the pipe is pulled will affect the
wall thickness of the finished product. In these machines a series of chains are used to pull
the pipe. Haul off units are easy to set up due to pneumatic clamping. These are highly
appreciated due to synchronization with extruder and feature of encoder system.

Figure1. 7 Haul off machine

2.2.8 Cutting Machine: A motor-driven circular saw cutter enables high-speed cutting
operation of the pipes. A chamfer tool is also incorporated along with the cutter. It’s
processing system that is used to cut the pipe automatically with a length setting by the
operator. The cutting system is controlled by PLC (programmable logic control).In front
of the cutter machine there is a rotor encoder that is used to measure the length of the
pipe this pipe length is sense by position sensor that is controlled by PLC. And also there
are many switches like limit switch, proximity switch to sense the position of the pipe.

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Figure1. 8 Cutting Machine View

2.2.9 Belling: A machine used to make a joint for connecting two or more pipes. It is a
processing system that is used to bell the corner part of the pipe. In this process system
there made many things in order to bell the pipe. When the pipe comes from the cutting
part the pneumatic sensor, sense the pipe immediately and the pipe get pressure by
pneumatic system and pressurized the pipe till it leaves the pneumatic valve. Next, the pipe
goes to resistor heater in order to hot for belling purpose. Then it goes to the next resistor
heater to get more heat for softening purpose. After that it goes to the belling machine to
get its belling shape, in this part there is position sensors and water control sensor. In this
case water is to cool the hot part of the pipe. Finally, there is oiling system which is used to
push the pipe from the holder.

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Figure1. 9 Belling Machine

2.3 Overall Electrical System Components found in APF

2.3.1 Motors

There are three kinds of motors mostly used in APF, i.e. three DC motor, induction motors,
synchronous motor.

2.3.1.1 DC Motor

2.3.1.2 Induction Motor

2.3.1.3 Synchronous Motor

2.3.2 Motor starting methods

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2.3.3 Motor testing

2.3.4 Components used in control circuit

2.3.5 PLC system found in the factory

2.4 Major duties of the intern

2.5 Challenge faced and measures

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CHAPTER THREE

3. Overall Benefits that We Gained from the Internship

We faced that the internship time was the most educating and challengeable time. We see how
well we have understood the literatures, theories and formulas we had taken in our previous
courses but when it comes to the actual world, it was hard to tell how competent we were. It is
very understandable that parallel to the theoretical part, experience is very important in real
world. Being familiar with the work flow is a key to understand ones role properly and be
able to make competent decisions.
For something that takes inputs there is something in return, a benefit. In our internship too,
there were some benefits gained accordingly. The benefits are discussed below.

3.1 Theoretical and Practical Skill

When we first started on the company everything was new for us. It was really fascinating
and inspiring to see and experience the lessons we have been learning for the past four years.
As it’s commonly practiced, most of the courses we took in class dealt with the theoretical
side of it. Some lecturers took the initiative and tried to illustrate the practical part of this
field by displaying different graphic images in their lecture or suggested electrical device and
equipment that were more or less illustrative or even show us in laboratory to show what the
actual work looked like. The theoretical concepts that we know before helps us to develop our
practical skill.

We spent most of our time with the APF electricians to develop our practical
skills, theoretical skills, working procedures, proper use of materials and identifying the right
material for the right purpose. This internship program provided us with the opportunity to
expand our horizon, broadening our intellectual knowledge and gives us a chance to improve our
theoretical and practical knowledge from this grateful experience. Generally, we gained the
following essential things.

Creative and logical approach to solve problems.

Clearly understand different electronic devices working principle and interconnection.

We understand the control and power distribution system in the industry

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Able to give maintenances for different electrical device which are used in industrial
application.

Able to apply our basic electrical knowledge to the solution of more advanced electrical
engineering problems.

To be familiar with the operation principle, control mechanism, and networking system
about programming logic controller (PLC)

To analys the starting and speed control mechanism of electric motors.

We got an experience to read and interpret information and ideas presented in electrical
documentation drawings for different types of electrical machines. All the electrical maintenance
and installation system is based on the electrical documentations designed by engineers.

We got the benefit in industrial problem solving capability in the company. To solve the
industrial problem we must correlate our theoretical knowledge, different instruction manuals,
and asking professional persons

3.2 Improving Team Playing Skills

We learn a lot how to improve interactions with our team members. When activities are done
in group the acceptability, reasonability and accuracy found to be always better than those
done individually. Therefore we really understand team work is important to strength the
effort to accomplish the task. Ideas that are raised in team work help us to see one thing in
different angles and to be a multi directional thinker for elaborating our knowledge regarding
the given issue.

We understand that for the proper functioning of a team, each member should have:

 Listen actively and Demonstrate reliability

 Good communication skill
 Cooperate and help others
 Shares openly and willingly
 Fast decision making skill
 Self-confidence

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3.3 Improving Leadership Skills

Leadership is one of the functions of management which including planning organizing stetting
leading and controlling. This internship program guides us to be an ethical and effective leader.
Now we have been able to observe that how can we have a good and effective leader. For
instance,

 Should have the ability to listen to others.

 Should have Visionaries.
 Should have Good speaking ability.
 Should have develop a good sprit among the employees.
 Supports the employees by encouraging and building their self-confidence.
 Supports the employees by answering their questions and by accepting their
suggestions.
 Closely observe the performance of the employees.
 Direct the performance of the employees at all major stages up to the completion of
the task.
 Should have risk takers.
 Should have given an award for effective employees in order to initiate other late
employees.

3.4 Work Ethics

These statements of intended conduct are expected of every member of the APF.

Respecting moral imperatives to society and human well-being.

Be honest and trustworthy.

Be punctual.

Be fair and take action not to discriminate.

Respect property rights (Honor copyrights and patents; give proper credit; not steal,
damage, or copy without permission).

Respect the privacy of others.

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Acquire and maintain professional competence.

Know and respect existing law pertaining to our professional work.

Generally work discipline or desired work behavior can be achieved only by obeying and
respecting the moral or ethical standards of profession. Ethical standards enable workers to
distinguish the right or desired way of conduct from the wrong ones. This helps workers to
develop good working environment and enables them to sustain good communication skills and
behavior with each other and with customers.

3.5 Entrepreneurship Skills

Entrepreneurship is defined as the process of designing, launching, and running a new business,
such as Start-up Company, offering a product, process or service for sale. Also defined as the
capacity and willingness to develop, organize and manage a business venture along with any of
its risk in order to make a profit. What we have seen regarding entrepreneurship is that
entrepreneurs are aware of not only what they are able to do but also what their limitations are.
They are ready to admit their weaknesses and reach measured decisions, which take in to account
their limitation.
Some of the common Entrepreneurship skills are:

Creative thinking

Problem solving

Need for achievement

Recognizing Opportunities

Willingness to take risk

 keep learning.

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CHAPTER FOUR

4. PROJECT AND CONTRIBUTION

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