INTERNSHIPE REPORT ON AMHARA PIPE FACTORY
Contents
CHAPTER ONE..........................................................................................................................................3
1. Background of Amhara pipe factory........................................................................................................3
1.1 Brief History (Introduction)................................................................................................................3
1.2 Vision, Mission and Objective of the factory.....................................................................................3
1.3 Main Products...................................................................................................................................4
1.2. Over All Organizational Structure.....................................................................................................4
CHAPTER TWO.........................................................................................................................................5
2. OVERALL INTERNSHIP EXCPERIANCE..........................................................................................5
2.1 Objectives of the Internship..............................................................................................................5
2.1.1 General objective........................................................................................................................6
2.1.2 Specific objectives......................................................................................................................6
2.2 Production Process of Amhara pipe Factory......................................................................................6
2.2.1 Mixing:.......................................................................................................................................6
2.2.2 Hopper:.......................................................................................................................................7
2.2.3 Extruder:.....................................................................................................................................7
2.2.4 Die and Mandrel.........................................................................................................................8
2.2.5 Vacuum Tank.............................................................................................................................8
2.2.6 Bath (cooling).............................................................................................................................9
2.2.7 Haul off.....................................................................................................................................10
2.2.8 Cutting Machine.......................................................................................................................10
2.2.9 Belling......................................................................................................................................11
2.3 Overall Electrical System Components found in APF.......................................................................12
2.3.1 Motors......................................................................................................................................12
2.3.2 Motor starting methods.............................................................................................................15
2.3.3 Motor testing.............................................................................................................................19
2.3.4 Components used in control circuit...........................................................................................20
2.3.5 PLC system found in the factory...............................................................................................23
2.4 Major duties of the intern...............................................................................................................24
2.5 Challenge faced and measures........................................................................................................25
CHAPTER THREE...................................................................................................................................26
3. Overall Benefits that We Gained from the Internship............................................................................26
3.1 Theoretical and Practical Skill..........................................................................................................26
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3.2 Improving Team Playing Skills..........................................................................................................27

3.3 Improving Leadership Skills.............................................................................................................28
3.4 Work Ethics......................................................................................................................................28
3.5 Entrepreneurship Skills....................................................................................................................29
CHAPTER FOUR.....................................................................................................................................30
4. PROJECT AND CONTRIBUTION......................................................................................................30
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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 and HDPE pipes. And under the second
category, it manufactures geomebrane sheets and greenhouse film/sheet. APF is a factory
awarded with ISO 900: 2015 quality management system certificates.
1.2 Vision, Mission and Objective of the factory
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 production alongside of creating job
opportunities and professionalism in the field.
Objective of APF
The factory has got the following objectives:
 To reduces the price of plastic products by 35% from that of the foreign purchase.
 To saves the foreign currency.
 To create job opportunities for many workers.
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 To supply its product with the reasonable price to contribute economic

development of the country.
 To support the socio-economic development of the Amhara Region in particular

and the overall development of the country in general.
 It gives value for the eco-environment friendly manner.
Values
 Satisfying customers
 Loyal to pay tax,
 Optimizing profit,
 Owning culture of group effort/work.
1.3 Main Products
 UPVC Pipes
 HDPE Pipes
 Geomembrane Sheet
 GreenHouse Film
1.2. Over All Organizational Structure
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GENERAL ASSEMBLY
Board of Director
General Manager
DGM
Legal Advisor
Support work process
Internal Audit
Technical Advisor /
Operational
Planning, system development
Safety and Training section

Production core
Work process HR Admin. & General service

support work process
Repair and
Commercial /Marketing
Maintenance
work process core work process
Quality and Safety

Procurement & Finance
core work process
support work process
organizational work flow
CHAPTER TWO
2. OVERALL INTERNSHIP EXCPERIANCE
2.1 Objectives of the Internship
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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 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
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Figure1. 6 Vacuum Tank
2.2.6 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.
Figure1. 5 Cooling Tank

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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
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
A DC motor is a mechanically commutated electric motor powered from direct current (DC).
The stator is stationary in space by definition and therefore the current in the rotor is
switched by the commutator also be stationary in space. This is how the relative angle
between the stator and rotor magnetic flux is maintained near 90 degrees, which generates the
maximum torque. DC motors have a rotating armature winding (winding in which a voltage is
induced) but non-rotating armature magnetic field and a static field winding (winding that
produce the main magnetic flux) or permanent magnet. Different connections of the field
and armature winding provide different inherent speed/torque regulation characteristics. The
speed of a DC motor can be controlled by changing the voltage applied to the armature or
by changing the field current. The introduction of variable resistance in the armature circuit or
field circuit allowed speed control. Modern DC motors are often controlled by power electronics
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systems called DC drives. The introduction of DC motors to run machinery eliminated the
need for local steam or internal combustion engines, and line shaft drive systems. DC
motors can operate directly from rechargeable batteries, providing the motive power for the first
electric vehicles. Today DC motors are still found in applications as small as toys and disk
drives, or in large sizes to operate steel rolling mills and paper machines.
2.3.1.2 Induction Motor

It is an AC motor that converts electrical energy in to mechanical energy in which alternating
current from a power source is fed through a primary winding and induces a current in a
secondary winding, with the parts arranged so that the resulting magnetic field causes a movable
rotor to rotate with respect to a fixed stator.
 In APF, there are many induction motors which are used to move from one process to
the other process.
Operation principle of induction motors
When the 3-phase stator winding are fed by a 3-phase supply then a magnetic flux of constant
magnitude but rotating at synchronous speed is set up. The flux pass through the air gap sweeps
past the rotor surface and so cuts the rotor conductors which, as yet stationery. Due to the
relative speed between the rotating flux and the stationary conductors, an emf is induced. The
frequency of the induced emf is the same as the supply frequency. Its magnitude is proportional
to the relative speed between the flux and the conductors. Since the rotor bars or conductors form
a closed circuit, rotor current is produced.
The causes which produce the rotor current are relative speed between the rotating flux of the
stator and the stationary rotor conductors. Hence to reduce the relative speed, the rotor starts
running in the same direction as that of the flux and tries to catch up with the rotating flux. Due
to the relative speed between the stator magnetic field and rotor magnetic field torque is induced.
There are four common conditions that can cause severe damage to three phase induction
motors.
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Figure 2.5 Induction motor
2.3.1.3 Synchronous Motor

Is doubly exited fed type and have direct current in their field windings and ac current in
armature windings. AC power is fed to the stator of the synchronous motor. The rotor is fed by
DC from a separate source. The rotor magnetic field locks onto the stator rotating magnetic field
and rotates at the same speed. While induction motors rotate with a slip, i.e., rpm is less
than the synchronous speed, the synchronous motor rotate with no slip, i.e., the rpm is
same as the synchronous speed governed by supply frequency and number of poles. Field
windings are the windings producing the main magnetic field (rotor windings for synchronous
machines); armature windings are the windings where the main voltage is induced (stator
windings for synchronous machines).
Operation principle of synchronous motor
Synchronous motor mainly runs on principle of magnetic locking between rotor and RMF
(Rotating magnetic field) .When two unlike poles are brought near each other, if the magnets are
strong, there exists a tremendous force of attraction between those two poles. In such condition
the two magnets are said to be magnetically locked. When 3 phase voltage applied to stator field
rotating magnetic field produces. This RMF rotates with synchronous speed. The synchronous
speed of a stator rotating magnetic field depends on the supply frequency and the number of
poles for which stator winding is wound.
Synchronous motor is a doubly excited machine i.e. two electrical inputs are provided to it. Its
stator winding which consists of a 3 phase winding is provided with 3 phase supply and rotor is
provided with DC supply. When DC supply given to rotor it acts like an electromagnet. As we
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know rotating magnetic field rotates with synchronous speed when two opposite poles of rotor
and RMF locked rotor also rotates with same speed of RMF in the direction of rotating magnetic
field. Hence synchronous motor rotates at one and only one speed i.e. synchronous speed.
But this all depends on existence of magnetic locking between stator and rotor poles. Practically
it is not possible for stator poles to pull the rotor poles from their stationary position into
magnetic locking condition. This is the reason why synchronous motors are not self- starting.
Figure 2.6 Synchronous motor
2.3.2 Motor starting methods

There are a number of three phase motor starters used in APF. These are;
 DOL (Direct on Line) starter
 Star- delta starter
 Forward reverse starter
a) Direct On Line Starter (DOL)
The basic DOL motor starter, consist of a contactor with a thermal overload relay that will trip in
the event of an overload condition. The DOL starter has the added feature in that it can be
operated by manual or automatic control devices.
 DOL control circuit: The DOL control circuit consists of a combination of switches
and auxiliary contacts where the operational behavior of the main contactor coil
relies from. When the RUN push button switch is pressed down, the control circuit
is complete which causes the electricity to proceed down to the coil of the main
contractor. The control circuit provides two interrupting contacts, one is the OFF
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push button switch which is manually pressed by a human operator to stop the motor
when necessary, and another one is the thermal overload . DOL motor controller is
most popular in terms of simplicity and control device availability: And it is suitable
for application with small capacity motors which does not cause too much high
inrush current that can pull down the supply voltage of the available power source
from the electricity supply grid. DOL does not necessarily need complex switching
devices to run the motor.
 DOL Power Circuit: The DOL motor starter consists of the most basic electrical
components for motor operation, these components includes switches and motor
circuit fault detection devices. A separate control circuit controls the DOL power
circuit illustrated here. The DOL control circuit activates the closing and opening of
the main contactor of the power circuit to run or stop the motor. Those contactors
automatically open the control circuit upon detection of motor overload current.
Figure2. 3 Controlling And Power Circuit of DOL
Advantages of DOL motor starters:
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a) Fail safe operation of the control circuit
b) Simple operation
c) Low initial cost
d) Remote stop and start features of control.
Disadvantages of DOL motor starters:
 No current limiting ability, therefore maximum current

occurs at start.
b) Star delta motor starting
A star delta starter is the most commonly used method for the starting of a 3 phase induction
motor. In star delta starting an induction motor is connected in through a star
connection throughout the starting period. Then once the motor reaches the required speed, the
motor is connected in through a delta connection.
Figure2. 4 Power And Controlling Circuit of Ctar Delta (from left to right)
Advantages and Disadvantages of Star Delta Starter
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The advantages are
 The method of starting reduces the inrush current to almost 2 to 3 times the FLC. While
in case of direct online starting in the delta the inrush current is almost 6-8 times of FLC.
 This is a comparatively cheaper method of reduced voltage starting of the motor.
 These are also used in industry as the power-saving device. The change over from star to
delta and vice versa is done as per the torque requirement of the motor. If a large motor is
installed and the load requirement is one-third of the motor capacity than the motor can
be run in star reducing the magnetizing current of the motor, thus saving power.
The disadvantages are
 Due to low starting torque sometimes, the motor may fail to pick up speed. The torque is
about 33% of the full load torque.
 The transition from star to delta will give rise to a current transient which neither good
for motor nor for the supply system.
 For conversion from star to delta, start and finish of each winding is to be brought out to
the motor terminal otherwise only three terminals are sufficient.
 As the transition from star to delta takes place in the starter, two separate cables are
required from the motor terminal to the starter.
 It requires higher maintenance compared to direct online starting.
c) Forward reverse electric motor starter
Starting the AC induction motor's rotation either in the forward or reverse direction with the push
of a button is made possible by the forward reverse control circuit.
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Figure2. 5 Control Circuit of Forward Reverse
Figure2. 6 Power Circuit of Forward Reverse
2.3.3 Motor testing
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2.3.4 Components used in control circuit

Contactor
Contactor is an electrically controlled switch used for switching an electrical power circuit,
similar to a relay except with higher current rating. A contactor is controlled by a circuit
which has a much lower power level than the switched circuit. Unlike circuit breaker, a contactor
is not intended to interrupt a short circuit current. Unlike general-purpose relays,
contactors are designed to be directly connected to high-current load devices. Devices
switching more than 15 amperes or in circuits rated more than a few kilowatts are usually
called contactors.
When current passes through the electromagnet (pins A1 and A2), a magnetic field is
produced, which attracts the moving core of the contactor. The electromagnet coil draws more
current initially, until its inductance increases when the metal core enters the coil. The moving
contact is propelled by the moving core; the force developed by the electromagnet holds the
moving and fixed contacts together. During this time the motor or any electrical output device
connected to the contactor is activated. When the contactor coil is de-energized, gravity or a
spring returns the electromagnet core to its initial position and opens the contacts, and hence
output devices turned off. Contactors are used to control electric motors, lighting, heating,
capacitor banks, thermal evaporators, and other electrical loads.
Figure 2.9 Contactor
Relay
Relay is an electrically operated switch. Many relays use an electromagnet to operate

switching mechanism mechanically, but other operating principles are also used. Relays are
used where it is necessary to control a circuit by a low-power signal (with complete electrical
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Isolation between control and controlled circuits), or where several circuits must be
controlled by one signal. Relays were used extensively in Telephone exchanges and early
computers to perform logical operations. A type of relay that can handle the high power
required to directly control an electric motor or other loads is called a contactor. Solid-state
relays control power circuits with no moving parts, instead using a semiconductor device to
perform switching.
Relay
Fuses
A fuse is an electrical safety device that operates to provide overcurrent protection of an

electrical circuit. When a high current flows through the circuit due to overloading
or short circuit, the wires gets heated and melts. As a result, the circuit is broken and current
stops flowing.
Breakers
A circuit breaker is an automatically operated electrical switch designed to protect an electrical
circuit from damage caused by excess current from an overload or short circuit. Its basic function
is to interrupt current flow after a fault is detected.
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Circuit breaker
Encoder
An encoder is a device, circuit, transducer, software program, algorithm or person that converts
information from one format or code to another. The purpose of encoder is standardization,
speed, secrecy, security, or saving space by shrinking size. Encoders are combinational logic
circuits and they are exactly opposite of decoders. They accept one or more inputs and generate a
multi-bit output code. Here the pipe factory uses it for speed control.
Impedance
Impedance is a device used to minimize starting current. When motor starts, the starting current
is too high that may damage the entire system. So it should be minimizes. To do this we use
impedance.
Sensors
Define a Sensor as an input device which provides an output (signal) with respect to a specific
physical quantity (input). It can also defined as a device that converts signals from one energy
domain to electrical domain.
The term “input device” in the definition of a Sensor means that it is part of a bigger system
which provides input to a main control system (like a Processor or a Microcontroller).
Sensors that we see in the factory are the following:
a) Proximity sensor
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A Proximity Sensor is a non-contact type sensor that detects the presence of an object. Proximity
sensors are used across a broad range of industrial and manufacturing applications. They’re used
to sense the presence of objects or materials and then either initiate some action or simply flag
their presence or absence. Key to their operation is that they don’t require physical contact with
the target or object being sensed. This is why they’re often called non-contact sensors.
Temperature sensor
It is a device used to detect the temperature of liquid, gas, etc. It commonly used in motor
control applications.
b) Thermocouple
A thermocouple is an electrical device consisting of two dissimilar electrical conductors forming

an electrical junction. A thermocouple produces a temperature-dependent voltage as a result of
seebeck effect, and this voltage can be interpreted to measure temperature. Thermocouples are
widely used as temperature sensors.
c) Photo Sensor
Like proximity sensor photo sensor is a non-contact type sensor that detects the presence of an
object. This sensor detects any object but proximity sensor detects metals.
d) Water Level Sensor
Water level sensor is a sensor used to control the level of water in the water thank, which is used
for cooling. It has high and low level sensor. Low level sensor send message to fill the Thank
when the water is low, while the high level sensor is used to stop the filling of water when the
Thank is full.
AC and DC Drive
AC Drive Characteristics
•AC drives utilize a solid-state adjustable frequency inverter which adjusts frequency and
voltage for varying the speed of an otherwise, conventional fixed speed AC motor.
This is achieved through Pulse-Width Modulation (PWM) of the drive output to the
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motors.
•Voltage and frequency are maintained at a constant relationship at any motor speed
to maintain a constant torque. This is known as the volts per hertz ratio.
•Integrated drive/motor packages available.
AC Drives are often the best choice for:
•Applications requiring full load torque at zero speed.
• Fast changing loads.
• Tight speed regulation.
• Coordinated speed control for multiple drive axes.
• Applications requiring increased starting torque.
• Precise closed loop speed regulation (to 0.01% and less) is required.
• High dynamic response.
• Web processes material handling sorter conveyors, metering pumps, extruders, and test
stands.
Dc Drive Characteristics
DC drives utilize a converter to transform AC current into DC current which is then fed to the
DC motor which is designed for adjustable speed operation. Speed changes are made by
increasing or decreasing the amount of DC voltage fed to the motor from the drive.
Usually offer the lowest cost for medium and high HP applications.
DC Drives are often the best choice when
• Environmental conditions surrounding the DC motor are reasonably clean and dry.
• The application requires a wide range of changing loads such as center driven winders.
• Motor speeds can reach 2500 RPM.
• Starting torques are greater than 150% or unpredictable.
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• Application HP requirements are medium to large.
2.3.5 PLC system found in the factory

Definition Programmable logic controller-is a special form of microprocessor-based controller
that uses a programmable memory to store instructions and to implement functions such as logic,
sequencing, timing, counting, and arithmetic to control machines and processes and is designed
to be operated by engineers with perhaps a limited knowledge of computers and computing
languages.
a. PLCs:
Are rugged and designed to withstand vibrations, temperature, humidity, and noise
Have interfacing for inputs and outputs already inside the controller
Are easily programmed and have an easily understood programming language that is
primarily concerned with logic and switching operations.
Typically a PLC system has five basic functional components in Siemens‟ automation which is
used by Amhara pipe factory. These are central processing unit, power supply unit, input output
module, interface module, and communications interface.
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Programming
device module Communication
(program and data interfacemodule
memory)
Signal Input interface Output To output

Processor
module interface
from devices
module
sensors like motors
Power
supply
Figure 2.1 Major components of Programmable logic controller (PLC)
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.
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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
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.
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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
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.
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 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.
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
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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.
CHAPTER FOUR
4. PROJECT AND CONTRIBUTION
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INTERNSHIPE REPORT ON AMHARA PIPE FACTORY

3.2 Improving Team Playing Skills..........................................................................................................27

1. Background of Amhara pipe factory

1.1 Brief History (Introduction)

1.2 Vision, Mission and Objective of the factory

The factory has got the following objectives:

 To saves the foreign currency.

 To create job opportunities for many workers.

 To supply its product with the reasonable price to contribute economic

 To support the socio-economic development of the Amhara Region in particular

 It gives value for the eco-environment friendly manner.

1.3 Main Products

1.2. Over All Organizational Structure

Planning, system development

Safety and Training section

Work process HR Admin. & General service

Quality and Safety

organizational work flow

2. OVERALL INTERNSHIP EXCPERIANCE

2.1 Objectives of the Internship

2.1.1 General objective

2.1.2 Specific objectives

2.2 Production Process of Amhara pipe Factory

Figure1. 3 Mixer Machine View

Figure1. 4 Extruder Machine

Figure1. 6 Vacuum Tank

Figure1. 5 Cooling Tank

Figure1. 7 Haul off machine

Figure1. 8 Cutting Machine View

Figure1. 9 Belling Machine

2.3 Overall Electrical System Components found in APF

2.3.1.2 Induction Motor

Operation principle of induction motors

Figure 2.5 Induction motor

2.3.1.3 Synchronous Motor

Operation principle of synchronous motor

Figure 2.6 Synchronous motor

2.3.2 Motor starting methods

 DOL (Direct on Line) starter

 Star- delta starter

 Forward reverse starter

a) Direct On Line Starter (DOL)

Figure2. 3 Controlling And Power Circuit of DOL

Advantages of DOL motor starters:

a) Fail safe operation of the control circuit

c) Low initial cost

d) Remote stop and start features of control.

Disadvantages of DOL motor starters:

 No current limiting ability, therefore maximum current

b) Star delta motor starting

Advantages and Disadvantages of Star Delta Starter

The advantages are

The disadvantages are

c) Forward reverse electric motor starter

Figure2. 5 Control Circuit of Forward Reverse

Figure2. 6 Power Circuit of Forward Reverse

2.3.3 Motor testing

2.3.4 Components used in control circuit

Figure 2.9 Contactor

Relay is an electrically operated switch. Many relays use an electromagnet to operate

A fuse is an electrical safety device that operates to provide overcurrent protection of an

Sensors that we see in the factory are the following:

A thermocouple is an electrical device consisting of two dissimilar electrical conductors forming

d) Water Level Sensor