Abduselam Jemal 0903478: 2. Abel Asfaw . .0903505 3. Bamlak Yirdagn .. 0903763

BAHIR DAR UNIVERSITY
BAHIR DAR INSTITUTE OF TECHNOLOGY
FACULITY OF ELECTRICAL AND COMPUTER ENGINEERING
DEPARTMENT OF ELECTRICAL ENGINEERING
STREAM: INDUSTRIAL CONTROL
HOSTING COMPANY: NATIONAL CEMENT SHARE COMPANY
(DIRE DAWA PLANT)
NAME OF INTERNS ID. NO.

1. ABDUSELAM JEMAL…………………………0903478
2. ABEL ASFAW………………….……………….0903505
3. BAMLAK YIRDAGN………………………….. 0903763
NAME OF MONITERS
1. Mr. HABTEMARIYAM
Feb, 2021
Bahir Dar, Ethiopia
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DECLARATION
We want to assured that this report belongs to us. We have done a project during the internship
program and is included as part of this report. We were fully engaged to write this report and
also to perform our project. Except we have taken from reference materials all the descriptions,
recommendations are our own. Finally, we are intended to tell you this document is a good
indicator of how much effort we made to go steps forward in the practical world by integrating it
with the theoretical knowledge.
Name of Advisor Signature Date

Mr. HABTEMARIYAM __________ __________
Name of Internees Signature Date

1. ABDUSELAM JEMAL _________ ________
2. BAMLAK YIRDAGN _________ _________
3. ABEL ASFAW _________ _________
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ACKNOWLEDGEMENT
Before all, our thank goes to almighty God for his support and protection of us throughout our
life. We thank national cement share company (NCSC) for accepting us as interns. We also
thank our mentor Mr. Habtemariyam, for helping us to bring this report and project in organized
manner. And we also thank the engineers of the company Mr. Mebratu and Mr. Melaku along
with all the electricians for their support to develop theoretical knowledge to practical skill. We
wish express our profound thanks to all those who helped us in well done the internship. Last,
but not least, we would like to thank our family, for their, encouragement, patience and support
throughout our internship time in every part of our problems.
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Table of Contents
DECLARATION ............................................................................................................................ ii
ACKNOWLEDGEMENT ............................................................................................................. iii
List of figures ................................................................................................................................ vii
List of tables ................................................................................................................................. viii
List of Acronyms ......................................................................................................................... viii
Executive Summery ....................................................................................................................... ix
CHAPTER ONE ............................................................................................................................. 1
1. Background of National Cement Share Company .................................................................. 1
1.1 Introduction ...................................................................................................................... 1
1.2 Vision, mission and objective of the company................................................................. 2
1.2.1 Vision ........................................................................................................................ 2
1.2.2 Mission ...................................................................................................................... 2
1.2.3 Objective of the company ......................................................................................... 2
1.3 Organizational structure of the Company......................................................................... 3
1.3.1 Task of each section .................................................................................................. 4
1.4 Key Stake Holders of the Company ................................................................................. 6
1.5 Production process in national cement ............................................................................. 6
1.5.1 Production Process .................................................................................................... 6
1.5.2 Production type ......................................................................................................... 8
1.5.3 Production capacity ................................................................................................... 8
CHAPTER TWO ............................................................................................................................ 9
2. Overall Internship Experience................................................................................................. 9
2.1 Objectives of Internship ................................................................................................... 9
2.1.1 General Objective...................................................................................................... 9
2.1.2 Specific Objectives.................................................................................................... 9
2.2 How we did get the company ......................................................................................... 10
2.3 Work section................................................................................................................... 10
2.4 Overall System Components and Operations ................................................................. 11
2.4.1 Power supply of the company ................................................................................. 24
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2.4.2 Controlling unit ....................................................................................................... 26
2.4.3 Relay ....................................................................................................................... 28
2.4.4 Input Devices .......................................................................................................... 29
2.4.5 Output Devices ........................................................................................................ 35
2.5 Major duties of the intern ............................................................................................... 43
2.6 Challenges faced and measures ...................................................................................... 43
2.6.1 Challenges ............................................................................................................... 43
2.6.2 The Measures Taken to Solve the Challenges ........................................................ 44
CHAPTER THREE....................................................................................................................... 45
3. Benefits Gained from the Internship ..................................................................................... 45
3.1 Theoretical knowledge and practical skills .................................................................... 45
3.2 Team playing skills ........................................................................................................ 46
3.3 Interpersonal Skills ......................................................................................................... 46
3.4 Leadership Skills ............................................................................................................ 47
CHAPTER FOUR ......................................................................................................................... 49
Project and contribution ................................................................................................................ 49
4. Project title: counter with automatic diverter ........................................................................ 49
4.1.1 Abstract ................................................................................................................... 49
4.1.2 Introduction ............................................................................................................. 49
4.1.3 Problem identification ............................................................................................. 50
4.1.4 Problem statement ................................................................................................... 50
4.1.5 Objective of the project ........................................................................................... 51
4.1.6 Significance of the project ...................................................................................... 51
4.1.7 Scope of the project ................................................................................................. 51
4.1.8 Limitation of the project.......................................................................................... 52
4.1.9 Methodology ........................................................................................................... 52
4.1.10 System design and overall operation....................................................................... 52
4.1.11 Simulation and result .............................................................................................. 53
4.1.12 Conclusion .............................................................................................................. 55
4.1.13 Recommendation..................................................................................................... 55
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4.2 Contribution.................................................................................................................... 56
CHAPTER FIVE........................................................................................................................... 57
5. Conclusion and Recommendation......................................................................................... 57
5.1 Conclusion ...................................................................................................................... 57
5.2 Recommendation ............................................................................................................ 58
5.2.1 Recommendation for NCSC ................................................................................... 58
5.2.2 Recommendation for the School ............................................................................. 58
5.2.3 Recommendation for the Industry Linkage............................................................. 59
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List of figures
Figure 1.1 Bird eye view of NCSC ................................................................................................. 1
Figure 1.2 Organizational structure ................................................................................................ 3
Figure1.3 Production process .......................................................................................................... 6
Figure 2.1 Working sections in NCSC 10
Figure 2.2 Gypsum crusher 13
Figure 2.3 Stacker 14
Figure 2. 4 (A) Bridge scraper reclaimer (B) Side scraper reclaimers 15
Figure 2.5 Bag filter 17
Figure 2.6 Ball mill 18
Figure 2.7 Rotary kiln 18
Figure 2.8 Weight feeder 19
Figure 2.9 Cement packer machine 21
Figure 2.10 Belt conveyor 23
Figure 2.11 Factory sub station 24
Figure 2.12 (A) LV panel of E 25 and (B) MV circuit breakers and display 25
Figure2.13 PLC sections 26
Figure2.14 operating cycle of CPU 27
Figure 2.15 Relays 29
Figure 2.16 Limit switch 30
Figure 2.17 Selector switch and push button 31
Figure 2.18 Radar flow meter 32
Figure 2.19 Temperature sensor (RTD) 33
Figure 2.20 Photo cell 34
Figure 2.21 Proximity sensors 35
Figure 2.22 Motors 36
Figure 2. 23 Operation flow of VFD 40
Figure 2.24 VFD device 40
Figure 2.25 LRS device 42
Figure 4. 1 Persons who count and direct packed cement 50
Figure 4. 2 Block diagram of the system ...................................................................................... 52
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List of tables
Table 2. 1 Power distribution of overall substation ...................................................................... 25
Table 2. 2 starting methods working section ................................................................................ 42
List of Acronyms
AC…………………………………………….Alternate current
CCR………………………………………......Centralized Control Room
CEO…………………………………………..Chief Executive Officer
CPU…………………………………………..Central Processing Unit
DC…………………………………………....Direct Current
DOL……………………………………….....Direct On Line
EELPA…………………………………..…..Ethiopia Electric Light And Power Authority
EMR…………………………………………Electro Magnetic Relay
LRS……………………………………….….Liquid Resistance Starter
LV…………………………………………....Low Voltage
MV……………………………………………Medium Voltage
NC……………………………………………Normally Closed
NCSC…………………………………………National Cement Share Company
NO…………………………………………….Normally Open
OPC…………………………………………...Ordinary Portland Cement
PPC……………………………………………Portland Pozzolanic Cement
PPE……………………………………………Personal Protective Equipment
RAM………………………………………….Random Access Memory
ROM………………………………………….Read Only Memory
SSR………………………………..…………Solid State Relay
TPD………………………………………….Ton Per Day
VCM…………………………………………Vertical Coal Mill
VRM…………………………………………Vertical Raw Mill
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Executive Summery
In this report, we gave some emphasis about what the NCSC is, when the company started the
production and where was it. In national cement there are three working sections namely: crusher
area, kiln area and cement mill. In this factory we have stayed for two months and during this
period we have stayed for about three weeks in each area. Basically the electrical system is
almost the same but there is machineries difference.
The overall internship activities, the knowledge we have gained, the problem we have identified
and the project that we designed to minimize the problem is explained. And also different
electrical devices, machines along with their uses and their control mechanism are briefly
discussed throughout this report. As we are assigned to this share company named NCSC
according to Bahir Dar Institution of technology university’s curriculums, starting from October
12 to December 15 /2021, over two month, we have tried to apply our classroom study to the
actual world and we have adapted a lot on social interaction with all coworkers of the company.
We also participated in maintenance of different machines with in the company. Beside to this,
we gave some recommendations to the company.
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CHAPTER ONE
1. Background of National Cement Share Company
1.1 Introduction
National Cement Share Company (NCSC) is one of the largest cement factories in Ethiopia. It
was established in November 2005 through a joint venture of East Africa Mining Corporation,
the Federal Government of Ethiopia's Privatization and Public Enterprises Supervising Agency
and others. Over the next few years, government shares were bought out by East African Mining
Corporation.
The company is located in Eastern part of Ethiopia right at the entrance of Dire Dawa city at 515
kilometers from the capital city of Ethiopia, Addis Ababa, in Dire Dawa Administrative Region.
The factory was the first cement plant in Ethiopia, which was established in 1936 by Italians.
This company has an experience of more than 74 year in cement production and it was
previously called "Dire Dawa Cement and Limestone Factory".
After renovating the old factory, the company has boosted the production from 150 Tons per Day
(TPD) to 400 TPD and is currently producing 3000 TPD clinker with the new plant. In addition
NSCS has planned to increase production capacity from 3000TPD to 5000TPD clinker. The
company is committed to the successful realization of the plan.[1]
Figure 1.1 Bird eye view of NCSC
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1.2 Vision, mission and objective of the company
1.2.1 Vision
 To be the preferred supplier of quality cement in the continent

 To became a world class cement by 2025
 To become the Leading Industrial group in the region.
 To support the country policies on the behalf of construction manner.[1]
1.2.2 Mission
 To supply products those are leaders in quality, cost, and customer satisfaction through
the integration of people, technology, and systems.
 To add values to the shareholders through better profitability by supplying our customers
with quality cement and competitive price.
 To produce and distribute cement products that exceedingly meets customer’s
requirement by adopting modern technology, qualified man power, eco-friendly and
socially accountable operation.
 To contribute positively to socioeconomic development of Ethiopia
 Establishing strong relationship with our customers and suppliers[1]
1.2.3 Objective of the company

 Delivering high quality cement from limestone and clay with affordable price to our
customers
 To sell produces in local market and abroad
 Economic uses of resource
 Promoting the product in a fair and ethical way
 Implementing competitive, productive, well-organized strategies
 Insuring strong, healthy, and transparent way of marketing[1]

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1.3 Organizational structure of the Company
Board of directors
Chief Executive
Officer
Planning and monitoring
Legal service
Internal audit service
Deputy CEO-plant Deputy CEO Chief financial Koka plant Deputy CEO
operation (marketing and sales) officer Plant service
Occupational
health, safety
& Sales & Public
environmental distribution Finance & relation
service department accounting service
(eastern region) department
Addis Ababa
Quarry and support
auto garage Sales & distribution service
ICT service
department department (central,
department
southern & south
Production Supply chain
eastern region
department management
department
Engineering
department Fleet operation
management Human
Quality control
department resource
department
management
Mechanical
maintenance General
department Service and
security
Electrical department
maintenance
department
Figure 1.2 Organizational structure
500 TPD plant

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In the company there are different sections that are involved in different jobs. But they work
through interaction.
1.3.1 Task of each section

1) Board of directors - hire the CEO, provide the overall direction and strategy of the
business, establish a policy based governance system. They reports to the shareholders.
2) Chief Executive Officer - Creating business plans, overseeing day-to-day activities,
supervising head of departments, directing organizational strategy, control and lead all
over the company, apply yearly plan and occupational program, check if the plan is
applied or not and follow up all over working process of the company.
3) Deputy chief executive officer - prepare reports for the CEO and board. Work as a CEO
in his/her absence.
4) Legal Services - Give advice and legal suggestion on legal issue and question; give
description and explanation about legal proclamation.
5) Planning and monitoring - Control, check and Prepare different occupational plan,
organize the management and working process, formulate expansion plans and
coordinate production process.
6) Internal audit service - Ensures that the organization is complying with relevant laws
and statuses, objectively assess a company's business; develop implement and maintain
internal audits policies and procedures in accordance with local and international best
practice
7) Finance Department - Follow up and realize financial planning, perform budget
preparation, indicate the direction of financial sources of the company, and controls the
collected finance
8) Supply chain management Department - this department handles the entire production
of flow of cement starting from the raw components all the way to delivering the packed
cement.
9) Production Department - Controls all production processes, supplies raw materials,
identifies product types, formulate plans to increase products etc.

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10) Seals & Distribution Department - Gathers marketing information, searches market
places, purchases raw materials and imputes, applies customer attracting activities, and
makes product advertising activities, study the quality, purchasing prices, and tactics of
selling the competitive company products.
11) Human Resource - this section is primary governed by the rule and regulation that was
formed in the co-ordination of both workers and the administration. It also holds the
structure hierarchy of the occupation of the type of employee, so when there is a gap
formed it announces a vacancy based on the job criteria that already exist. Also gives
some training assignment for the employers.
12) Maintenance Section -This section stands for the maintenance of electrical and
mechanical parts of the company. For example; controlling the power supply and
maintaining an electrical and mechanical system which is mostly on the machine in order
to minimize maintenance cost.
13) Occupational health & safety service - this section provides the required Personal
Protective Equipment (PPE) for employees and gusts including intern students. By
considering the possibility of accident, it’s mandatory to wear PPE. Any employee who
doesn’t wear PPE is punished up to 5 day salary. Equipment’s provided by the company
are: - Safety shoes, helmet, Gloves, Face shields, Safety belt, Dust filters and Ear muffs.
During our stay in the company we are provided with only helmet.
14) Fleet operation management department - this department is responsible for the
logistics of the company. Their responsibilities include purchasing and maintaining
vehicles for deliveries, handling the transportation service of employees and coordinating
logistics.
15) ICT service department - this section is responsible for the architecture, hardware,
software, and networking of computers in the company. This section is responsible for
ensuring if the employees have full access to the computer systems.
16) Quality control department - This section is mostly determined how much the raw
materials and the product at each steps are qualified and checked whether the incoming
goods are the same as the standard or not.

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1.4 Key Stake Holders of the Company
Any person or entity interested in a particular business is called a stakeholder. They are affected
by the business activity, and they may be part of the core decision-making team. Internal and
external stakeholders may have different interests and priorities, possibly leading to conflicts of
interest. Internal stakeholders are owners, managers, and workers. External stakeholders are the
customers and the supplier although the owner of NCSC is East Africa Sharing Corporation.
1.5 Production process in national cement
1.5.1 Production Process
Quarry of Crusher
raw
Raw mill
materials
Raw mix silos grinded raw mix silos
Clinker
Cement
mill
Packed
cement
Additives (gypsum, pumice) Cement silos
kiln Clinker
silo
Figure1.3 Production process

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 Mining – the raw material like Limestone and basalt are blasted from rock quarries,
nearby the plant, by boring the rock and setting of explosives with little impact on the
environment due to the employment of modern technology.
 Transportation - once the huge rocks have been fragmented, they are transported to the
plant in dump trucks.
 Crushing - the fragmented rock is delivered to the crushers where it is reduced in size by
crushing or pounding to chunks approximately 1 ½ inches in size for limestone. There are
different types of crusher in the plant (limestone crusher and gypsum crusher).
 Storage - each of the crushed raw materials is transported separately in to silos, where it
later will be added in specific amounts according to the particular type of cement being
produced.
 VRM – from the silos, the raw materials (limestone, clay, basalt) are transported in to
Vertical Raw Mill (VRM) in a proportional mixture. The mill exerts mechanical action to
grind the materials to very fine sizes so that it can be sacked by fans in to the bag house
and then to silo. The mechanical action in the mill homogenizes the raw materials in the
mill.
 Raw material homogenization - this process takes place in silos for obtaining a
homogenous mix of the material.
 Calcinations – is the process of heating a substance to a high temperature, but below its
melting point, to bring about thermal decomposition. In this process Rotary kiln come
into play. Inside, up to 1400 ℃, the raw material (limestone, clay and basalt) is
transformed into clinker: small, dark gray nodules 3-4 centimeters in diameter.
 Clinker silo: one clinker is produced from the calcination process inside the kiln it is
stored in clinker silo.
 Cement milling - the clinker is grind by different-size steel balls along with additive
materials (gypsum, pumice) based on the type of cement being produced, to extend
cement setting times. The finest particles from the mill is sacked with the help of fans and
stored in to cement silos.
 Cement packing and loading – the cement stored in the silos is extracted mechanically
with an interaction of air slide and bucket elevator and transported to packer silo which is

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smaller in size with storing capacity of 20 tones. Then it will be packed in 50Kg sacks
and loaded in the trucks.
1.5.2 Production type
Currently the factory supplies two types of cement products, namely PPC (Portland Pozzolanic
Cement) and OPC (Ordinary Portland Cement) both to internal and export markets. These
two types of cement differ from each other in terms of components, cost, application, quality,
setting time and etc.
PPC – is quality cement with 32.5R strength class. It is used for floors, houses, dams (where
there is sulphate construction) and for construction which doesn’t require early strength.
OPC - is quality cement with 42.5R strength class. It is used for constructions such as bridges,
dams, heavy foundations and for other constructions that requires early strength.[1]
1.5.3 Production capacity
Currently National Cement is capable of producing;-
 3000 tons of clinker per day
 80,000 bags cement per day
 1.2 million ton cement per year [1]

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CHAPTER TWO
2. Overall Internship Experience
2.1 Objectives of Internship
The objective of an internship is to expose us to a particular job and a profession or industry. We
might have an idea about what a job is like, but we won’t know until we actually perform it.
Internship helps us to understand if work is what we thought what it was, if we have the training
and skills to do it and if it is something we like. It helps us to facilitate reflection on experiences
obtained in the internship and to enhance understanding of academic materials by application in
the internship setting.
2.1.1 General Objective
Some of the general objective of internship includes:

 To provide us the opportunity to test our interest in a particular career before permanent
commitments are made
 To develop skills and techniques directly applicable to our careers.
 To provide us the opportunity to develop attitudes conducive to effective interpersonal
relationships
 To provide us with an in-depth knowledge of the formal functional activities of a
participating organization
 To gain confidence and know - how for future employment
 To apply our classroom knowledge into practice
2.1.2 Specific Objectives
The specific objectives of this internship are:

 To receive an introduction to an organization within production industry and to gain a
better understanding of its design and structure.
 To provide intensive field experience allowing for hands-on computer work.
 To apply what was learned during coursework (theory, skill development,
professionalism) to the working world.
 To find future employees

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 To allow the organization to benefit from a trainee who has gained knowledge about the
latest technologies available and to benefit from the trainee’s objective viewpoint.
 To allow us to assume responsibilities of a non-Intern staff member and be able to
function with a minimum of supervision.
 To help us to make better career choices in the future.
 To allow us to prepare for our future non-Internship job by seeking potential places of
employment, practicing resume and cover letter preparation, gaining references, and
interviewing if applicable.
2.2 How we did get the company
As the NCSC is the first cement plant in the country, we thought that most of the company’s
machineries and controlling mechanisms would be older. But all the controlling mechanisms
have automation so that only few centralized control room (CCR) officers can control the whole
production process through SCADA. We didn’t expect plc to have such applicable function in
factories but most of the machineries here in NCSC have plc as a controller. We were so
surprised to see such modern controlling mechanism. We have seen motors and there controlling
mechanism that we didn’t seen before.
2.3 Work section
In the company there are three working sections. These are crusher area, kiln area and cement
mill area.
A. Crusher area B. Kiln area
C. Cement meal
Figure 2.1 Working sections in NCSC

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Crusher area: Crusher area is an area where production of cement begins. As the raw
materials for cement production are huge in size, it needs some reduction, and this reduction in
size takes place in the crusher area. List of machineries that are found in this section are:
 Crushers
 Bag filters
 Belt conveyors
 Weight feeder
 Reclaimer
 Stackers
Kiln area: it is an area where the calcination process takes place. The three raw materials,
limestone, clay and basalt, are grinded together and burned in this area in order to produce
clinker. List of machineries in this area are:
 Rotary kiln
 Weight feeder
 Bag filter
 Bucket elevators
 VRM
 VCM
Cement mill: this is an area where the kiln output, clinker, is grinded along with the additive
materials, gypsum and pumice, to produce cement. List of machineries that are found in this area
are:
 Ball mill
 Weigh feeders
 Bucket elevators
 Packers
 Belt conveyors
2.4 Overall System Components and Operations

NCSC uses modern technologized hydraulic machines i.e. they needs water, oil and power
supply. Here are some of the main machineries used in this factory for clinker and cement
production which we had exposed to, are:

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 Crushers
 Stacker
 Reclaimer
 Bag filter
 Vertical Coal mill (VCM)
 Rotary kiln
 Ball mill
 Classifiers and separators
 Weight feeder
 Packers
 Material transporting systems
1 Crusher: - is a multi-dimensional machine which is designed to reduce large size materials
into smaller size materials. It is normally low speed machine, uses gear box to decrease the
speed, that are designed for breaking large sized stones, like limestone and gypsum, even having
a size with a diameter of over one and half meter. The purpose of crusher is to reduce the size of
the material for making them ready and usable in the next process. There are many types of
crushers, some of them are: - Jaw crusher, gyratory crusher, roll crusher and hammer crusher.
Crushers that are used for crushing limestone and gypsum in NCSC are hammer crusher.
Hammer crusher consists of a high-speed usually horizontally shaft rotor turning inside a
cylindrical casing. The crusher contains a certain amount of hammers that are pinned to the rotor
disk that crushes the raw materials. Feed is dropped to the crusher from the top of the casing and
it is crushed between the casing and the hammers. The feed rate to a crusher is controlled by
Variable speed drive machine known as apron feeder. After crushing, the material falls through
the opening in the bottom to the receiving conveyer belt.
Crushers run by 6KV motors that has a power of 2500 kw and controlled by liquid resistance
starter (LRS)

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Figure 2.2 Gypsum crusher
2 Stacker: - is a large machine used in bulk material handling. Since raw materials for cement
production arrival time at a plant is much shorter as compared to their consumption time, they
require to be stored. Due to this, stackers are needed to create stockpiles of the raw materials.
The main purpose of stackers is storing materials on storing area that is an open yard here in
national cement for limestone, clay, basalt and inside the storing room for gypsum and coal.
Stacker can move horizontally along the rail in either high speed or low speed. The motor that
controls the horizontal movement of the stacker is controlled by VFD controlling mechanism.
The conveyor belt used in stackers is driven by pulleys, which in turn is driven by an electric
motor.
Most stackers are electrically powered by way of trailing cable. There are basically two types of
cable trailing. These are:-
 Power cable rotating drum and

 control cable rotating drum
The stacker we have seen in national cement can be controlled either manually from the site or
remotely from CCR. But currently it is controlled only from site.

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Figure 2.3 Stacker
3 Reclaimer: - The material stored in stockpiles needs to be reclaimed to suit its gradual
consumption in the plant. Therefore, stockpiles needs reclaimer machine to reclaim the material.
Since the stackers and reclaimers have to store and reclaim material over a long distance, they
are mounted on rails.
There are wide varieties of reclaimers to suit specific need but the one that NCSC is using is
scraper type. In scraper reclaimers, scraper blades (toothed rectangular steel plates) are attached
to two parallel strands of chain at regular interval. The travel of chains along with scraper blades
drags the material from the stockpile and discharges it on the receiving belt conveyor. Then the
conveyor transports the material in to the silos. There are three silos in the crusher area: one for
limestone, one for clay and one for basalt.
Reclaimers can horizontally move along the rail in both directions. They can move either at high
speed or low speed. So there are two forward reverse motors responsible for each speed type.
The high speed movement which is controlled by the larger motor is used when the reclaimer
needs to change position without reclaiming. The low speed movement which is controlled by
the smaller motor is used at the time of reclaiming. There is also magnetic clutches to stop the
reclaimer immediately.
Like that of stackers, reclaimers are also electrically powered by way of trailing cable. There are
two cables one for power circuit and the other for control circuit.
Bridge scraper reclaimer (for limestone) and side scraper reclaimer (for coal and gypsum) are the
two types of reclaimers used here.

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Bridge scraper reclaimers are used where reclaiming must be carried out from the face of a
stockpile.
Side scraper reclaimers are used for open as well as covered stock yards. Side Scraper reclaimers
are used extensively for low capacity non-blending applications mainly in cement plants for
additives and coal.
A B
Figure 2. 4 (A) Bridge scraper reclaimer (B) Side scraper reclaimers
4 Bag filter: - is an air pollution control device and dust controller that removes gas released
from commercial process into the environment. NCSC use bag filters to control emission of air
pollutants. It use long cylindrical bags, solenoid valve, air tank, screw motor (only for larger
bag filters), rotary motor etc.
The purpose of the cylindrical bag is to isolate the dust from dusty air that enters the bag filter
through hopper (large funnel-shaped containers used for storing and discharging material).
The dusty air enters to the hopper as it is sacked by a fan. The solenoid valve is responsible for
opening the valve so that the air from the air tank purges the dust accumulated on the bag.
The valve opens as per programmed time in the PLC. The air tank is used for storing air and
releasing the compressed air for purging purpose whenever the solenoid valve is open. The

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screw motor is used for collecting the purged dust and particles inside the bag filter. The rotary
motor is used to rotate the metal plate (rotary) which rotates slowly in order to receive the
purged dust and particles so as to drop it into the belt conveyer.
The metal plate acts as a valve as it allows and blocks the movement of purged particles. Air
enters the bag house through hoppers and is directed into the bag house compartment. The gas
is drawn through the bag; either on the inside or the outside depending on cleaning method,
and a layer of dust accumulated on the filter media surface until air can no longer move
through it. When a surface pressure drop occurs, the cleaning process begins. Cleaning can
takes place while the bag house is online (filtering) or is off line (in isolation) and when the
compartment is clean normal filtering resumes.
There are three main types of bag filters. These are:-Pulse jet bag filters, Shaker bag filters and
Reverse air bag filter. Pulse jet bag filters are used here in NCSC.
Most bag filters are found on material drop sites, sites where material changes its direction
from one conveyer belt to the other, as drop causes dusty air.
The main uses of bag filter is
 Separation of gas from material
 Protection of the environment
 Material recovery

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Figure 2.5 Bag filter
5. Ball mill: - A ball mill is a horizontal cylinder partly filled with steel balls and it rotates on its
axis. The balls will have different sizes and different weight proportion so that large balls deal
effectively with feed and the small once are responsible for producing fine product. In the ball
mills the material and the grinding media (spherical balls or steel ball) are brought together in a
rotating tubular compartment. The material and the grinding media are lifted some distance
above the ground due to the rotation of the mill. Closed Circuit Mills: - In these mills the output
from the mill is fed to a separator by a bucket elevator for separating into product and rejects.
The rejects are returned to the mill inlet. The closed circuit mills have a better control on the
particle size.
The factory has two ball mills each with a capacity of grinding 83 tons/hour of the raw materials
and when working with 24 hours the mills has a capacity of grinding 4000 tons/day, then the
quality control laboratory takes a sample from the output of the mill and tests the quality of the
raw material and reports the result to the computer control unit via telephone.

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Figure 2.6 Ball mill
6. Classifiers and Separators: - In cement industry air classifier is better choice and it is
economical. Following classifier air and fine material separation is accomplished by techniques
like bag house.
7. Rotary kiln: - Burning of raw materials in cement production is takes place in kiln along with
the preheaters. Kiln is a pyro processing device used to raise materials to high temperature in a
continuous process in order to bring chemical change. It is a cylindrical vessel, inclined slightly
to the horizontal, which rotates slowly about its axis. The material to be processed is fed into the
upper end of the cylinder. As the kiln rotates, material gradually moves downward towards the
lower end, and may undergo a certain amount of stirring and mixing. NCSC uses modern vertical
shaft kiln for the production of clinker and has capacity of producing 3000 TPD cement clinker.
The rotary kiln is the only devise in NCSC that rotated by DC motor.
Figure 2.7 Rotary kiln
8. Weight feeder: - is a variable speed small conveyor incorporating belt weighing and speed
control system used for the continuous weighing and feeding of materials with normal or
difficult flow ability.
A weight feeder consists of belt conveyor with a driving drum, a tail drum, the conveyor belt and
the supporting stations for the top and bottom belt. The weighting components are load cells.
The belt weight feeder extracts a product from a storage hopper, silo, through the constant cross-
section and according to fixed reference flow-rate (set point), adjusts the extracted volume by
varying the belt speed in such a way as to keep a constant weighed flow-rate. Depending on the

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expected material flow, the automation controls the speed of the dosing belt, as well as the speed
of the upstream extractor. The centralized control system is then kept informed of the quantity of
materials inserted in to VRM and ball mills and compares it with the flow indicated by the
operator.
The manufacture of clinker and cement requires a constant and controlled amount of raw
materials. For this purpose, the weight feeder regulates the flow of materials (limestone, basalt
and clay) in to VRM and materials like clinker, gypsum and pumice in to the cement mill with
high dosing accuracy.
Figure 2.8 Weight feeder
9. Packer: - Cement packing machine is a cement bagging equipment for cement packing in the
finished cement production, also known as cement packer. It is mainly used in automatic packing
of cement.
As for cement packing machine types, most of them are either fixed type or rotary type. Fixed
cement packing machines refers 1- 4 mouth packing machines; the cement filling is completed
by manually moving bag. Rotary cement packing machine refers to 6-14 mouth type; the packing
machine rotates to complete cement filling without manual work. In NCSC all the four packers
are rotary types.
Advantages of rotary cement packing machines are:-

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 Reduces the dynamic vibration and create good conditions for measuring and weighting.
 Highly automatic: basically realize automation, filling, metering, bag dropping, and other
actions are completed by one set of cement packing plant automatically and continuously.
 Friendly working environment, if the bag weight is less than the specified value, the bag
will not drop. If the bag falls off unexpectedly, the gate will be closed immediately and
filling will stop.
 Easy for maintenance.
Working principle of rotary cement packer

Cement powder is first conveyed to the vibrating screen by the bucket elevator after it is
screened out of impurities, it enters the intermediate bin for storage. When all of these
preparatory measures are finished, cement storage in the bin is fed into the feeding device of the
packaging machine.
The packer adopts the eccentric material feeding method. Cement powder in the feeding device
continuously enters the rotary bin controlled by the level transmitter mounted outside the bin. Its
rotary speed is regulated by frequency conversion and the rotary direction is clockwise. After
that, the cement powder will be sent into the discharge hopper and be continuously filled in the
bag under the action of a high-speed rotating impeller.
There are four types of filling process:

(1) When the bag weight is more than 0.8kg, the microcomputer control system considers that
the bag has been inserted. The cylinder does not close and the bag is continued to be filled. When
the bag weight reaches the set target value, the microcomputer control system makes the cement
bag drop automatically when it reaches the drop position.
(2) When the bag weight is less than 0.8kg, the microcomputer control system considers that the
bag is not inserted. The solenoid valve works and the cylinder is closed
(3) When the bag is dropped, the microcomputer control system stops filling by controlling the
electrical components

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(4) When the filling fails to reach the set target value but reaches the bag dropping position, the
equipment will carry out a secondary filling, and the cement bag will not drop automatically until
the set target value is reached.
After cement bag is dropped 0n the receiving belt conveyor, it will pass through small
rectangular cleaner which cleans the floating ash from the bag. Finally the bags are transported to
the waiting trunk by the belt conveyor. To reduce dust pollution during the filling process, a dust
collecting system is formed by the cone intermediate disc and the dust collecting plate. The
returned material of each discharge nozzle can be sent back to the bucket elevator by the screw
conveyor.
The whole cement filling process is controlled by electricity, except manual inserting bag.
cement bag pressing, opening and closing of discharging mouth, Cement filling, weighing and
measuring, automatic bag dropping and other functions are completed automatically, so as to
reduce mechanical faults and ensure the fast operation of packaging equipment.
Figure 2.9 Cement packer machine

10. Material Transporting System
There are at three means of material transporting system from section to section. These are:
1. Belt conveyor
2. Bucket elevator
3. Air lift

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1. Belt Conveyors:
Although there are many types of conveyer systems, National cement mainly uses belt conveyors
which are used in transporting products (packed cements) and raw materials (like limestone,
basalt, clay, gypsum etc.) in straight line or through changes in elevation or direction. A belt
conveyor system consists of two or more pulleys and rollers, with a closed loop of carrying
medium (belt) that rotates about them. One of the pulleys is powered from an electric motor so as
to move the belt and the material on the belt forward. The powered pulley is called the drive
pulley while the unpowered pulley is called the idler pulley. The motor powering the pulley
rotates at high speed so we need gearboxes and clutch for controlling mechanism.
Gearbox is used inorder to meet the required speed for the conveyor belts. As the motors run at
high speed and the belt doesn’t need to run in that speed we use gearbox so as to reduce the
speed. Clutches are used to stop the motor immediately. As the motor doesn’t stop at the instant
we pressed the stop push button it may cause some unnecessary material flow as it rotates the
belt along with itself, so to avoid this flow we use clutch (hydraulic or magnetic) as it stop the
motors shaft from rotating immediately. Most belts rotate only in one direction (only forward)
and some rotates in both forward and reverse directions.
Belt conveyors have some safety systems. The belt conveyors installed in national cement
includes tripping mechanisms such as rope switch and drift switch along the length of the
conveyor. This safety switches allow for workers to immediately shut down the belt conveyor
when a problem arises.
Rope switch will stop the belt if there is any unnecessary material recognized and if any problem
arises on the worker while he/she is working, anyone can pull the rope to stop the belt
immediately.
Drift switch will stop the belt if the belt starts loosing it’s alignment along the structure.In the
idler pulley there is speed sensors that sense the speed of the belt and sends feedback to the DCS
then to CCR. There is a weight sensor under the belt which measures the amount of material that
the belt is transporting

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Figure 2.10 Belt conveyor
The belt conveyor transporting system used in transporting of materials:-

 From crusher to the stockpiles then to silos,
 From proportioning to raw mill,
 From proportioning of clinker silo, pumice and gypsum stockpiles to cement mill ,
 From packing to loading,
2. Bucket elevator: it is another widely used means of transporting system in national cement.
Wherever there is certain inconvenience for belt conveyors, bucket elevator is the best choice for
transportation. Some of the inconvenience is: When the temperature of material to be transported
is too high for belt like immediate clicker output, bucket elevators are preferred. When the rout is
too sloppy i.e. when there is a significant height different between the start and destination of
material, there would be a back flow of material due to gravity. Therefore, it is better to use the
technology of bucket elevator.
The drive mechanism looks almost the same as that of belt conveyors. The flow of material is:
 From air slide output to raw meal silo,

 From rotary cooler output to clinker silo,
 From cement air slide output to cement silo are accompanied by bucket elevator.
From this, it is possible to see that bucket elevators are intended to do their task as per the reason
of selection mentioned earlier.
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3. Air slide: As the name itself indicates air slide transporting system uses air blown by blower
fans. As the air vibrates, due to the slope of the air slide, material will go towards the intended
direction. Usually air slide transports very fine materials in raw meal and cement meal. Air slide
transports material when the flow is:
 From raw meal output to raw meal bucket elevator
 From cement meal output to cement meal bucket elevator and others
2.4.1 Power supply of the company
As the power supply required by the factory is high, it is directly supplied from EELPA. NCSC
receives an incoming power of 132KV having a frequency of 50 Hz to the main substation of the
company. In the main substation, the incoming 132KV is changed in to 6.3KV by a transformer.
Figure 2.11 Factory sub station
Transformer is a static device that changes one voltage level to another voltage level without
changing the frequency. In NCSC, the transformer which changes 132KV (high voltage) in to
6.3KV (medium voltage) is step down transformer.
Once the voltage is changed into 6.3 KV it is transmitted in to electric rooms, from E 21- E 27,
where it is directly used by 6KV motors or it is again changed in to 400V and supplied for the
LV panel.

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A B
Figure 2.12 (A) LV panel of E 25 and (B) MV circuit breakers and display
Overall power distribution
Table 2. 1 Power distribution of overall substation
Electric room Incoming voltage Supply area

The 6.3 KV is supplied for
E 21 6.3 KV 6KV motors that run the two
crushers.
The 400V supplied for the LV
E 22 400 V panel and the crusher area.
The 6.3 KV is supplied for
6.3 KV changed in to 400 V row mill motor and fan motor.
E 23 & E24 The 400V is supplied for kiln
inlet area.
E 25 400 V supply kiln outlet area
E 26 6.3 KV Supply the two ball mills
E 27 400 V Supply the LV panel for
cement mill area

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All the transmission system is controlled by substation automation using SCADA, which is a
recent system for electrical distribution monitor and control. Benefits of this system are:
 Visibility of the network operation
 Accurate and consistent information of the system
 Fast fault identification, isolation and restoration
2.4.2 Controlling unit
There are two types of controlling mechanisms of machine in the company. These are PLC
system and relay system.
Programming Logic Controller (PLC)
PLC is a digital computer used for the automation of various electro-mechanical processes in
industries such as control of machinery on factory assembly lines. It also is a special form of
microprocessor-based controller that uses programmable memory to store instructions and to
implement functions such as logic, sequencing, timing, counting, and arithmetic in order to
control machines and processes. Input devices (that is, sensors such as switches) and output
devices (motors, valves, etc.) in the system being controlled are connected to the PLC. The
operator then enters a sequence of instructions, a program, into the memory of the PLC. The
controller then monitors the inputs and outputs according to this program and carries out the
control rules for which it has been programmed.
Parts of PLC
From Sensor Power supply To
solenoids
Contact
Input
Processor Output Alarms
Push button module
module
Contactors
Limit switch
Programming
Etc. device
Figure2.13 PLC sections

The PLC system has the following main parts or units.

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1. The power supply: - it provides the constant voltage level required by the PLC. As the
main supply is AC, the rectifier converts the AC into DC typically 24V. Generally the
power supply unit: Is typically non-redundant. Hence a failure of the power supply can
cause the control system to fail.
2. Processor or central processing unit (CPU): -is the brain of the PLC. It consists of
microprocessor, memory chip and other integrated circuits to control logic, monitoring
and communication. PLC is a dedicated controller i.e. it will only process one program
over and over again. One cycle through the program is called a scan time and involves
reading the inputs from the other modules, executing the logic based on these inputs and
then updated the output accordingly. The scan time happens very quickly (in range of
1/100th of the second).
Start scan
Internal checks
Scan inputs
Execute program logic
Update outputs
Figure2.14 operating cycle of CPU
3. Memory: The memory stores data and program that the CPU needs to perform various
functions. The program memory receives and holds program instruction. Data memory is
used to temporarily hold data generated from processor or acquired through I/O devices.
There are two memory elements in a PLC system:
 Read-Only-Memory (ROM) gives permanent storage for the operating system
and fixed data used by the CPU.

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 Random-Access Memory (RAM) is used for the user’s program. This is where
information is stored on the status of input and output devices and the values of
timers and counters and other internal devices.
4. Programming devices: is used to enter the required program into the memory of the
processor. The program is developed in the device and then transferred to the memory
unit of the PLC.
5. Input / Output Unit: The input/output unit provides the interface between the system
and the outside world, allowing for connections to be made through input/output channels
to input devices such as sensors and output devices such as motors and solenoid valve.
Every input/output point has a unique address that can be used by the CPU.
2.4.2.1.1 Operation principles of PLC
Programmable logic controllers function by interpreting data coming through their inputs and
depending upon their state, turning on/off their outputs. They are programmable via software.
PLCs function using ladder logic programming.
There are three states of operation of PLC
1. Detect incoming signals
2. Process it
3. Generate outputs to control various devices
2.4.2.1.2 PLC Programming Language
Ladder diagram: is a logical method of displaying the control logic which, based on the inputs
determine the outputs of the program. The ladder is made up of a series of “rungs” of logical
expressions expressed graphically as series and parallel circuits of relay logic elements such as
contacts, timers etc. Each rung consist of a set of inputs on the left end of the rung and a single
output at the right end of each rung.
The vendor of PLC that is used in NCSC is semen’s sematic 7.
2.4.3 Relay
Relays are switches that open and close circuits electromechanically or electronically. Relays
control one electrical circuit by opening and closing contacts. When a relay contact is normally
open (NO), there is an open contact before the relay is energized and when a relay contact is

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Normally Closed (NC), there is a closed contact before the relay is energized. In either case,
applying electrical current to the contacts will change their state.
Relays are either electromechanical relays or solid-state relays. In electromechanical relays
(EMR), contacts are opened or closed by a magnetic force. While in solid-state relays (SSR),
there are no contacts and switching is totally electronic.
Relays involve two circuits: the energizing circuit and the contact circuit. The coil is on the
energizing side; and the relays contacts are on the contact side. When a relays coil is energized,
current flow through the coil creates a magnetic field. A relays useful life depends upon its
contacts. Once contacts burn out, the relays contacts or the entire relay has to be replaced.
Figure 2.15 Relays
2.4.4 Input Devices
Input devices are devices that are input to PLC to tell the operating condition of a certain system.
These input devices are mainly called sensors. A sensor is a device that measures a physical
quantity and converts it into a 'signal' which can be read by an observer or by an instrument.
Sensor is any device that uses electricity to sense a change in something, and then through a
voltage or current change, send a signal to a device that captures this information. Sensors can
give analog or digital output. An analog sensor gives an output proportional to the measured
variable. Such analog signals have to be converted to digital signals before they can be input to
PLC ports. Sensors that give digital or discrete, that is on/off, outputs can be easily connected to
the input ports of PLCs. Some of commonly used sensors found in NCSC are listed below.

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1. Switch – in electrical engineering switch is an electrical component that can connect or
disconnect the conducting path in electric circuit, interrupting the electric current or diverting
it from one conductor to another.
1.1. Limit switch - is an electromechanical device that consists of an actuator mechanically
linked to a set of contacts. It is operated by a physical force applied to it by an object as it is
used to detect the presence or absence of an object. When an object comes into contact with
the actuator, the devices operates the contacts to make or break an electrical connection. In
NCSC limit switches are found in diverters, LRS motor starters, in order to limit the
machine travel.
Figure 2.16 Limit switch
1.2. Selector Switch - is manually operated multi-position switch that selects a particular circuit.
In NCSC as the machines can be controlled from either site or CCR, selector switch is used.
Such a switch is usually rotary also called selector is usually adjusted by a knob. Selector
Switch works on a general principle, they contain a simple selector switch on the front of the
panel, and a broad range of potential contact combinations (via the contact blocks), on the
inside of the enclosure. Selector switches are available in 2, 3, or 4-position versions, and
are often used when more than one control option is needed. In this factory all the selector
switches has three positions. The central position represents maintenance, which means
while the machines are being maintained it need to be prevented from start. So if the knob is
in maintenance position neither site operators nor CCR officers can start the machine. The
right position represents local, which means the machine is started and stopped only from
local control box that is found in site. The left position represents remote, which means the

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machine is controlled only from the CCR. No one can start or stop the machine from local
control box while the selector’s knob is in the left position.
Figure 2.17 Selector switch and push button

1.3. Pushbutton - A push-button or simply button is a simple switch mechanism for controlling
some aspects of machine or a process. It is also known as momentary switch as it causes a
temporary change in the state only when the switch is physically actuated. An automatic
mechanism (i.e. a spring) returns the switch to its default position immediately afterwards,
restoring the initial circuit condition. In NCSC every machine is started and stopped by
pushbutton. In the control circuit of each motor a red NC stop pushbutton is used to stop the
motor and a green NO start pushbutton is used to start the motor.
1.4. Radar flow meter – is a device used to measure the level of the materials inside the silo and
it is usually installed at the top of the silo. As the name suggests it uses radar technology for
materials level detection. As it is non-contact level measurement, it is widely used in
industries. It consists of three fundamental components.
 A radar antenna: in this system it works as a transducer between the empty space in
the silo and the electromagnetic signal source or receiver. The antenna receives the
process signals and transfers them to the receiver.
 Solid-state oscillator: it functions as an electromagnetic signal transmitter. The
solid-state oscillator sends out electromagnetic wave in the direction of the surface of
the materials in order to measure the depth or level of material without any physical
contact.
 Receiver and signal processor system: is the hardware microprocessor that
converts the received signal in to reading. The signal processor performs the
computer data conversion to digital reading.

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Working principle of radar flow meter
The working principle of radar flow meter is a function of time of flight. As the flow meter is
used as a sensor itself, it can be said that the electromagnetic signals are sent from the sensor.
The solid-state oscillator that is installed in the radar level sensor setup oscillates electromagnetic
waves to the material surface. The distance can be measured considering oscillator as a reference
point and material surface as the destination. Once electromagnetic wave hit material surface, the
surface itself reflects a pulsating signal to the radar antenna. The antenna transmits the signal to
the receiver. As the receiver collects the signal returning pulse reflection, the time taken for
reflection is calculated. The time to level calculation is performed by the signal processor. Once
the signal processor translates reflection time into distance traveled that is considered as the
depth of the material according to time of flight.
Figure 2.18 Radar flow meter

1.5. Temperature sensor: is an electronic device that measures the temperature of its
environment and converts the input data into electronic data to record, monitor, or signal
temperature change.
At each stage in cement manufacturing, from grinding to packing we need to check and
control the temperature of each of the processes and the machineries in order to get the
desired clinker quality.
The type of temperature sensors that are found in NCSC are RTD and Thermocouples
1.5.1 Resistive Temperature Detector (RTD): is a temperature sensor based on the fact that
the resistance of a metal increases as the temperature rises. It is one of the most accurate
temperature sensors. By measuring the resistance of the metal, its temperature can be
determined. Several different pure metals (such as platinum, nickel and copper) can be used in

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the manufacture of RTD. In NCSC this type of sensors are found in oil stations of 6KV motors
and in the pre-heater cyclones.
1.5.2 Thermocouples: is a sensor that measures temperature. It consists of two different types
of materials, joined together at one end. When the junction is heated, a voltage is created that can
be correlated back to the temperature as:
Where α, the Seebeck coefficient, is the constant proportionality

A thermocouple circuit must contain at least two dissimilar materials and at least two junctions.
Thermocouple measures temperature difference (T1 – T2) between two junctions and the output
voltage Vo of a thermocouple circuit depends only on the difference between junction
temperatures (T1-T2).
In NCSC this type of sensors are found in
 smoke-box,
 preheater cyclone,
 kiln inlet, outlet and inside the rotary kiln
As it is capable of withstanding high temperature and high concentration of clinker dust, it
monitors the temperature of the hot gases recovered from the rotary kiln and from the preheater
tower.
Figure 2.19 Temperature sensor (RTD)
1.6. Pressure sensors: is a device for pressure measurement of gases or liquid. This device
generates an electrical signal as the function of imposed pressure. The type of pressure
sensor that is found in NCSC is strain gauge pressure sensor.
1.7. Photocell: is a sensor that allows us to detect light. It is a resistor that changes resistance
depending on the amount of light incident on it. There is a switch in a photocell that will

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disconnect when the light intensity around is bright, and connect when the light intensity
around is dark.
Figure 2.20 Photo cell

Working principles of photocell
Photocell works by light dependent resistance principle. This principle states that resistance
value will decrease when exposed to small light intensity (dark) and due to this it allows the flow
of electric current, which turns on the light. When the photocell is exposed to light the resistance
value increases and resists the flow of an electric current in to the lamp due to this the lamp will
be turned off.
In NCSC the main purpose of the photocells is turning the exterior lights on at sunset and off at
down automatically. Because they sense ambient light levels, photocells automatically adjust to a
seasonal change in the day and night cycle. It is placed outside a building so as to sense darkness
and the time of day in order to modulate lights.
1.8. Proximity sensor: this are types of sensors that are used to sense the presence of objects or
materials and then either initiate some action or simply flag their presence or absence. These
sensors don’t require physical contact with the target or object being sensed and often called
non-contact sensors. The most common types of proximity sensors are:
 Capacitive proximity sensor
 Inductive proximity sensor
 Optical proximity sensor

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 Laser proximity sensor
 Ultrasonic proximity sensor etc.
The type of proximity sensor that is widely used here in NCSC is inductive type which is used in
many applications. Some of them are listed below:
 As a motion sensor: inductive type proximity sensors are found in each and every belt
conveyers in order to check if the belt is working properly and running at the required
speed.
 In the packing machine there are two inductive type proximity sensors. The first one is
used to signal the filling coil of the machine in order to fill the empty bag with cement,
and the second one is used to signal the drop coil in order to drop the 50KG bag in to the
receiving belt conveyer.
Figure 2.21 Proximity sensors
2.4.5 Output Devices

The output ports of a PLC are relay or opto-isolator, depending on the devices that are to be
switched on or off. Generally, the digital signal from an output channel of a PLC is used to
control an actuator, which in turn controls some process. The term actuator is an output device
that transforms the electrical signal obtained from PLC into some more powerful action, which
then results in control of the process.
Some kinds of actuators that are found and used here in NCSC are; motors, timers, electrical
control relays, solenoid valves, and contactors.

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2.4.5.1 AC Motors
An AC motor is an electric motor driven by an alternating current (AC). There are two main
types of AC motors, depending on the type of rotor used. The first type is the induction motor or
asynchronous motor; this type relies on a small difference in speed between the rotating
magnetic field and the rotor to induce rotor current. The second type is the synchronous motor
which can rotate exactly at the supply frequency.
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 national cement factory, there are many induction motors which are used to move from one
process to the other process. These motors are ranged from smaller motors, like screw and rotary,
having a power rating up to 3KW and line voltage of 380-400V to larger motors , like fan motor
and mill motor, with a power rating up to 2500KW and line voltage of 6000V.
Figure 2.22 Motors
Motor starting methods in NCSC
Different starting methods are employed for starting induction motors because Induction Motor
draws more starting current during starting. To prevent damage to the windings due to the high
starting current flow, we employ different types of starters. The starting methods of the motors in

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NCSC are DOL (Direct Online), star delta, forward reverse, VFD (Variable Frequency Driven)
and LRS (liquid resistance starter).
Common components for most of the starting methods are listed and explained below:
i. Circuit barker – is an automatic operated electrical switch designed to protect an
electric circuit from damage caused by excess current from an over load or short circuit.
Its basic function is to interrupt current flow after a fault is detected.
ii. Push button – is a switching mechanism that completes an electric circuit when we press
on it. When it’s on, a small metal spring inside makes contact with two wires, allowing
electricity to flow. When it’s off, the spring retracts, contact is interrupted and current
won’t flow. The body of the switch is made of non-conducting plastic.
In DOL and star delta starting mechanism we use two push buttons, one with normally
open contact and the other with normally closed contact, but in forward reverse starting
mechanism we use two start NO push buttons and one NC stop push button to control the
motor.
1. Normally open (NO) – there is no connection till you push the button.
We use it as a start button.
2. Normally closed (NC) – here the switch conducts normally but
interrupts the circuit when you press on it.
They work as long as we press on them as they are momentary switches.
iii. Contactors – are electromagnetically operated switches that provide a safe and
convenient means for connecting and interrupting branch circuits. They are mainly used
to control machinery which uses electric motors. It consists of a coil which connects to a
voltage source. Very often for Single phase Motors, 230V coils are used and for three
phase motors, 415V coils are used. The contactor has three main NO contacts and lesser
power rated contacts named as Auxiliary Contacts [NO and NC] used for the control
circuit. A contact is conducting metal parts which completes or interrupt an electrical
circuit.
 NO-normally open
 NC-normally closed
iv. Over Load Relay (Overload protection) – is used to prevent burnout and to ensure
maximum operating life for an electric motor. Under any condition of overload, a motor

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draws excessive current that causes overheating. Overload relays are employed on a
motor control to limit the amount of current drawn. The overload relay does not provide
short circuit protection. This is the function of over current protective equipment like
fuses and circuit breakers, generally located in the disconnecting switch enclosure.
Overload relays are renewable and can withstand repeated trip and reset cycles without
need of replacement. Overload relays cannot, however, take the place of over current
protection equipment. Overload relays can be classified
a. Thermal Relay - As the name implies, thermal overload relays rely on the rising
temperatures caused by the overload current to trip the overload mechanism. This
type of relay is used here in National Cement for constructing the control circuit.
b. Magnetic Relay - Magnetic overload relays react only to current excesses and are
not affected by temperature.
c. Electronic Relay - Electronic or solid-state overload relays provide the
combination of high-speed trip, adjustability, and ease of installation. They can be
ideal in many precise applications.
I. Direct on line starter
The simplest form of motor starter for the induction motor is the direct on line starter. It consists
of a Circuit Breaker, Contactor and an overload relay for protection. The contactors are
electromagnetic type which can be opened by the thermal overload relay under fault conditions.
Typically, the contactor will be controlled by separate start and stop buttons, and an auxiliary
contact on the contactor is used, across the start button, as a hold in contact. I.e. the contactor is
electrically latched closed while the motor is operating.
II. Star- delta starter
This is another motor starting method that is used in NCSC. It is a type of reduced voltage
starter. This starting method is used for reducing the starting current of the motor without using
any external device or apparatus. It reduces the inrush current by a factor 3 compared to DOL
starter. The starter can be used with all squirrel cage induction motors that are delta-connected
for normal operations. It consists of contactor, overload relay, timer, circuit breaker, and push
buttons (start and stop).

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III. Forward reverse starter
It is used to run the motor in both sides forward and reverse. The forward reverse motor control
is used in a system where forward and backward or upward and downward movement in the
operation is needed. It is simply obtained by interchanging any two of its three terminals. In the
control circuit both the forward and reverse contactors interlocked in a way that only one
contactor should be in closed condition whiles the other is in open condition.
Materials used in the construction of forward reverse control circuit are
 Circuit barker
 Over load relay
 Contactors
 Push buttons
IV. Variable Frequency Driven (VFD)
This is another motor starting and controlling mechanism used in national cement. A variable
frequency drive (VFD) is a motor control device that protects and controls the speed of an AC
induction motor. A VFD can control the speed of the motor during the start and stop cycle, as
well as throughout the run cycle. VFDs are also referred to as adjustable frequency drives
(AFDs). VFDs are used in applications where:
 Complete speed control is required
 Energy savings is a goal
 Custom control is needed
Working principle of VFD
VFDs convert input power to adjustable frequency and voltage source for controlling speed of
AC induction motors. The frequency of the power applied to an AC motor determines the motor
speed, based on the following equation:
 N = speed (rpm)
 fe = frequency (Hz)
 p = number of motor poles

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Figure 2. 23 Operation flow of VFD

The above VFD show as five separate sections:
1. AC supply: Comes from the facility power network (typically 380 V, 50 Hz AC)
2. Rectifier: Converts network AC power to DC power
3. Filter and DC bus: Work together to smooth the rectified DC power and to provide clean
DC power to the inverter
4. Inverter: Uses DC power from the DC bus and filter to invert an output that resembles
sine wave AC power.
5. An AC supply from the inverter to the motor
Figure 2.24 VFD device

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The benefits of using VFD are:-
 Energy savings
 Reduces power when not required
 Fully adjustable speed (pumps, conveyors, and fans)
 Controlled starting, stopping, and acceleration
 Dynamic torque control
 Versatility
 Advanced overload protection
 PLC-like functionality and software programming
 Digital inputs/outputs (DI/DO)
 Analog inputs/outputs (AI/AO)
V. Liquid Resistance Starter (LRS)
LRS is another motor starting methods used here in national cement. Wound rotor motors use
resistance in the rotor circuit to control torque and speed. That resistance is liquid rheostat and it
allows for smooth resistance change.
A liquid rheostat consists of a tank of water mixed with a chemical called soda ash that alters the
water’s conductivity in a specific way. It’s important to monitor the water on a regular basis and
maintain the desired conductivity by adding water or soda ash as needed. Inserted in the tank are
three conductive plates attached to the rotor windings of the induction motor. The motor has
these windings brought out to three rings for carbon brush connections. The purpose of the this
brush is collecting the current from the rotor through the slip ring and it’s made from graphite as
it has high melting point, The three plates are attached by the mechanism small reversible motor
that can lower or rise the plates in the solution. When the plates are most of the way out,
(minimum across area submerged) the resistance is maximized. When the plates are all the way
in, (maximum across area submerged) the resistance is minimized. The amount of resistance
across the rotor assembly controls the speed/torque characteristics of the motor.
In the LRS two sensors are also installed with the system. These are level sensor and temperature
sensor. The level sensor is used to detect the level of the water in the tank. The water level may
decrease due to different reasons like a leak in the water tank. When the water decreases from the
level, the system will sound an alarm and it makes the contactor to trip so as to stop the motor
from running unless water is filled on time.

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The temperature sensor is used to sense the temperature of the motor while it is running. If the
motor temperature rises beyond the predetermined level, the sensor makes the motor’s contactor,
on the control circuit, to automatically trip in order to stop the motor from running which in turn
protects the motor from possible damage.
Once the motor started with low speed, it will gradually increases its speed and when the motor
runs in its full load, the resistance will be out of the system and the LRS is used to check the
operating temperature.
Figure 2.25 LRS device
Table2. 2 starting methods working section
Motor starting methods Working area
Direct on line In bag filter, oil stations, most belt

conveyor, fan
Star delta Air compressor
Forward reverse Some belt conveyors, Damper,
VFD Weight feeder
LRS Crusher, mill and VRM motors

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2.5 Major duties of the intern

Internship provides the opportunities to build a relationship with the company, network with
other people in the field and gain valuable first-hand experience. It gives us the knowledge and
experience we need to be confident in our career activities. We understand that our duties include
the following tasks.
 Obey the rules of the company
 Work the given tasks in the company with the guidance of the company supervisor and
Assisting company operators
 Write and submit reports on each area
 To be Committed to work
 To be reliable and punctual
 Making problem solving project

2.6 Challenges faced and measures
2.6.1 Challenges
During our stay in national cement we faced many challenges that make our time a little bit
difficult over there. Those challenges are listed below:
 Lack of personal protective equipment
 as we are not familiar with the staff members, they don’t tell us anything unless they are
asked
 some of the technicians are not well skilled, so when we had questions they either
confuse us or they don’t answer at all even though they are willing to tell us how the
machine works and the internal electrical component
 we were unable to use the company’s Wi-Fi as it is locked and they are unwilling to give
us the password
 since the machineries had high sound, it makes difficult to hear some of the explanations
from our supervisors
 some of the working sections are dusty
 we were unable to get the manual for some machineries

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 Since we were theoretical student, it was difficult for us to know even some of the
electrical instruments
2.6.2 The Measures Taken to Solve the Challenges
For each of the above challenges here are the lists of measures that we take:
 As the company makes wearing PPE mandatory and they only provide helmet, we bought
safety shoes, eye glass, face shield (mask) by our own
 In order to overcome the communication problem, we started taking part in their
conversation and we started asking questions in site about each and every electrical
related components and processes
 For questions that are not well explained by electricians, we start searching for details in
the internet
 For the explanations that we missed due to the sound problem, we start asking them again
in the office
 By taking the necessary precautions like by shielding our face and by wearing eye glass
we try to learn in the dusty environment
 We searched on the internet to get the manuals for some machineries
 For the electrical components that we don’t have exposure in the past, we ask the
electricians what it is and how it woks

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CHAPTER THREE
3. Benefits Gained from the Internship
The internship time was the most challenging time. We examine ourselves how much we
understand from the lecture classes and how the theories and formulas that we took in our
previous courses align with the practical world. It is obvious that along with 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 (output), a benefit. In our internship too, there were some
benefits gained accordingly.
3.1 Theoretical knowledge and practical skills

When we first started in 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 three and half
years. As it’s commonly practiced, most of the courses we took in class dealt with the theoretical
side of it. The theoretical concepts that we developed in the class helped us during our internship
time.
We spent most of our time with the national cement factory electricians to develop our practical
skills, theoretical skills, to understand working procedures, to learn how to use materials properly
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 maintenance for some electrical device which are used in industrial
application.
 Able to apply our basic electrical knowledge to the solution of more advanced
electrical engineering problems.
 Effective assessment and management of risk, resource and time.

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 To be familiar with the operation principle, control mechanism, and networking system
of programming logic controller (PLC).
 To analysis 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 as all the electrical
maintenance and installation system is based on the electrical documentations designed
by engineers.
 How to solve industrial problem by correlating our theoretical knowledge with the
required instruction manuals and asking professional persons for problems beyond our
skill.
3.2 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:
 Good communication skill
 Fast decision making skill
 Self-confidence
 Respect each other’s
 Listen each other’s
 Treat each other
 Encourage team members to share ideas.
3.3 Interpersonal Skills
Interpersonal skills are the skills that we use every day when we communicate and interact with
each other. We have seen that without effective communication skills, an employee cannot
succeed in the workplace. If communication can fail or if a message can be understood in
different ways, it will be understood in the way which does the most harm. During our internship
time we understood that, people with good interpersonal skills tend to be able to work well in a

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team as they are able to communicate effectively with other colleagues. Generally we have
gained the following interpersonal communication skills at national cement.
 Communication skills: which in turn covers:
 Verbal communication-what we say and how we say it
 Non-verbal communication-what we have communicate without word
 Listening skills-how we interpret both the verbal and non-verbal message sent by
others
 Emotional intelligent: being able to understand and manage our own and other’s emotion
 Conflict resolution and mediation: working with each other’s to resolve interpersonal
conflict and disagreement in a positive way
 Problem solving and decision making: working with others to identify, define and solve
problem, which includes making decisions about the best course of action
 Listening skill
 Forwarding precise messages or instructions
 We do not dictate or criticize a person's work in front of others and understanding about
their needs
 We are interested in the people communicating with us
 We learn from one another interaction by correcting our faults
3.4 Leadership Skills

Leadership, a critical management skill, is the ability to motivate a group of people toward a
common goal. A leader is a person who has strong principles, courage, and dedication to a clear
vision. A person who is in the position leadership seeks optimal solution to problems and should
be smart enough to manage those individual whom he/she is leading and must possess leadership
quality and ability to handle intricate interpersonal relationships effectively within a company to
increase productivity. For effective leadership we understood that personal values like
confidence, effective communication and devotion are very important role. We have learnt how
to satisfy customers and works without any felling which makes them happy and productive. We
also develop the ability how to lead a person who is not willing to take his responsibility and
how to make him a productive worker by giving advice and other measurements.
During our internship period, we have understood the following leadership techniques:

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 We have seen how each worker is controlled and organized to perform its day to day
activities. Among all other managements we have understood that human resource
management is the most important one.
 We have actually observed the method of controlling; the working time and amount of
work done by each worker so that the work proceeds according to the work plan.
 For effective leadership we understood that personal values like confidence, effective
communication and devotion are very important.
 If there is, conflict between the consultants leader must resolve the conflict in a good
way with his problem solving method or negotiate them.
Finally we identify the following listed items as a key to develop our leadership skill:
 Getting and giving information

 Understanding group needs and characteristics
 Knowing and understanding group resources
 Managing the group

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CHAPTER FOUR
Project and contribution
4. Project title: counter with automatic diverter
4.1.1 Abstract
In response to today's highly competitive business environment, companies are forced to analyze
and improve their existing manufacturing system continuously to minimize production losses,
due to production disturbances, that hinder the system efficiency, performance and reduce
profitability. A major problem at one of the production lines of NCSC, which is packing process,
is related to counting the number of packed cement which leads to the stop of the packing
machine which intern decreases the production capacity.
The Purposes of this project is to design counter with automatic diverter for the line to increase
production rate, minimize production loss and save the company from related crises. To
implement this project we used plc to design the ladder diagram and to simulate it. We use one
photoelectric sensor to detect the presence of the packed cement and send signal to the counter.
We also used one piston which moves forward reverse to divert the flow of packed cement in the
production line.
4.1.2 Introduction
Today's production systems in NCSC are required to deliver high efficiency and productivity,
since the demand for cement has been rising. Productivity improvement is one of the core
strategies towards manufacturing excellence and it also is necessary to achieve better financial
and operational performance. Improvement can be in the form of correction of ineffective
processing, simplifying the process, optimizing the system, reducing variation, maximizing
throughput, reducing cost, improving quality and reducing set up time.
Increasing productivity can be achieved in so many ways. The first step is all about identifying
pain point of the current workflow. Next we need to analyze the people, technology and process
required for production as well as procedures and resource available across the company.
This project relates automatic counter with diverting mechanism whereby packed cement
delivered from packing machine to be counted and in predetermined number diverted from the
travelling line to the next line.

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4.1.3 Problem identification

In NCSC we identified some problems which have direct impact on production efficiency. Some
of them are:-
 In the packing machine bag insertion is manual. So if the man who inserts the bag miss
by any chance there is product loss for few seconds until the load sensors sends signal to
the filling coil to close. So in order to minimize this problem we suggested them to insert
sensors that detects the presence or absence of the bag and send signal to the filling coil
 As the still balls used for grinding raw materials has different sizes, they are separated
manually during maintenance. To overcome this problem we suggest them to use
magnetic separating system.
 Feeding the raw materials for crushers is operated manually through dozers. This means
the crusher hopper always needs to be checked.by a person. To modernize the system, we
suggested them to use level sensors to know the level of the material.
 The counting and diverting mechanism for flow of packed cement is manual.
4.1.4 Problem statement
There are four packing machines in NCSC. A single packer has two loading conveyor belt.
After the packed bag dropped on the belt by dropping coil then moves forward towards the
truck where it is to be loaded. Counting the number of bags required is done by man, and
another man will divert the flow of packed cement to the next line, when the desired number
is reached. As this system has direct impact on the efficiency of the system, we designed a
counter with automatic diverter using plc, sensor and piston.
A B
Figure 4. 1 Persons who count and direct packed cement

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4.1.5 Objective of the project
General objective of the project

 This project aims to design a program for counter and automatic diverter.
Specific objective
 Study and analyze the problem in detail
 Perform all the pre-design procedures.
 To develop a plc program
 To simulate the designed program
4.1.6 Significance of the project
This project has a number of significance. The primary significance of the project is to reduce
human labor as counter and diverter of packed cement, since this process needs 24 men to be
done but according to our project we only need three persons.
Another significance of the project is it provides better service for customer. There is no turning
back because of an error in counting, once the truck is loaded. This means there is Weight Bridge
at the entrance door of the company to measure the weight of the truck. If a fault happens while
counting, the trunk is not allowed to leave. Loaded truck should be equal to the weight of truck
before loaded plus the weight of the loaded cement. So this means our project facilitates the
workflow of the company and saves time of customers and employees.
Since the counting and diverting is done by human labor, an error can be caused. Due to this
error the whole packing process should stop until the problem is solved so this reduces the
productivity of the company.
Last but not least this project was also a great educating scenario for us all interns. It was a great
practice in guiding us through all the steps in performing a project.
4.1.7 Scope of the project
This project will focus on the design of counter and automatic diverter. It enables us to count the
number of packed cement and divert packed bags flow to next line. This includes design of
ladder diagram and simulation using semen’s sematic 7 plc programming software.

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4.1.8 Limitation of the project
Limitation of this project is that it requires PLC to be executed. So this needs cost as plc is
expensive.
4.1.9 Methodology
Our background research was done through different technique. We have been going through
manuals, design books and journals to understand the basic principle and modifies, and all the
necessary data for this project was collected through five different techniques:
i. Staff interviews,
ii. In-site observation
iii. Data collection,
iv. Reading manuals, and
v. Review of equipment
Once the required information was collected, the data was analyzed, filtered and documented.
Such procedure allows us to identify critical points and potential problems to be solved in the
current and desired situation of the packaging process.
4.1.10 System design and overall operation
In order to design and simulate the project we use sematic manager, one photoelectric sensor that
senses the presence and absence of packed cement and send signal to the counter in the plc
program. We also use piston that divert the flow of the packed cement.
Sensor PLC Piston
Power supply
Figure 4. 2 Block diagram of the system

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4.1.11 Simulation and result

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Network 1 master switch
Network 2 counter
Network 3 convertor
Network 4 comparator
Network 5 timer
Network 6 piston expansion
Network 7 comparator
Network 8 timer
Network 9 piston retraction
4.1.12 Conclusion
To sum up all and conclude our project, we have earned a lot during our stay in this internship
program at NCSC. And we have worked on this project on a problem we pointed out in the
manufacturing process of the company, particularly packing process, and proposed a new
designed system to make better manufacturing process.
We have included all the needed predesign procedures in our paper work, related with all the
study introductory, data collection, analysis, feasibility studies, Design procedures, Simulation
and illustration.
During our project work here, we had gone through all the steps required, and this step was filled
with new challenges and new ideas to beat these challenges. And we have earned great
experience in each and every step we made. Since this project integrates the concepts of
Electrical Engineering disciplines, we have gained a lot in doing it so. Alongside with learning
how to manage and work on a successful deign as an Engineer.
4.1.13 Recommendation
First and for most we recommend NCSC to make an overall overview on our designed Project
and support our idea so as to solve the mentioned problem in the particular line.
We also recommend those whom concerns to put further progressive works and studies on
developing this idea furthermore.

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4.2 Contribution
As the main work of the electricians in the factory is maintenance, either preventive or
corrective, we participated as much as we can.

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CHAPTER FIVE
5. Conclusion and Recommendation
5.1 Conclusion
All in one, we think it would be fair to say that the internship program has been an enlightening
experience .We tried to put what we have been learning in the university, which is theoretical
knowledge, into practice and we got insight into practical work. The internship helped us to gain
the exposure to real-world problems and issues that, some of them, perhaps are not found in
textbooks. So we can say it was the time for us to challenge our knowledge. It also helped us to
recognize the environment that we will join after graduation.
During our internship period we have gained practical skills such as:
 Identifying many electrical and control devices that are installed in the automation system
of the factory.
 We had been familiar with different electrical inputs (sensors) to PLC and different
output devices installed to control the production of the company.
 We have gotten enough experience on how to use hand tools and how preventive and
corrective maintenance are done.
 We have gotten a better skill, experience and personal qualities in the working
environment.
 We also understood that replacing relay control systems by PLC had a great benefit on
the production process.
 Find out what it’s like to work in business environment.
 Investigate organization cultures and learns career- related skill.
Generally, the internship helped us to upgrade our theoretical knowledge and improve practical
skills, team playing skills, leader ship skills, interpersonal communication, written and oral
communication skill, and be aware of ethical issues. We perceive this opportunity as big mile
stone in our career development, we will strive to use gained skills and knowledge in the best
possible way, and we will continue to work on our improvement, in order to attain career
objectives.
The internship also helped us to find out what our strengths and weakness are. This helped us to
identify the skills and knowledge that must be improved in the coming time.

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At last this internship was a useful experience and has given us new insights and motivation to
continue in the field of electrical engineering.
5.2 Recommendation
5.2.1 Recommendation for NCSC
 To work on safe environment, the company should think on providing PPE’s for
intern students
 The work load and the payment of employees are uncompensated and due to this
some of the engineers are leaving the company. So they should improve the wage
for employees
 The company should employ additional electricians as there is work load in every
section
 We would like to address the employees working discipline. Most of the
employees in the company are frustrated due to their wage, so they should do
their job ethically and ask for payment improvement in ethical way
 Supervisors in the company should give enough time for the students. As we see
in the company, everything is done by the endeavor of the student. The human
resource management should think about this so as to decrease the load of the
student
 The company should build a network to identify employees with skill problems
and give them enough training so as to make them well skilled
 The company should release the pocket money on time
 The air released, due to damage of the air bag, from the company is polluting the
environment, so they should replace the damaged bag with the new one as soon as
possible
5.2.2 Recommendation for the School
 Three or fourth months only is not enough for the students to know the external
nonacademic world. If it possible, more time must be given for this internship
time from the five year. If it is not possible, giving more time for laboratory,
workshop and experiment class may improve the student’s ability to know more
knowledge than theoretical studying

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5.2.3 Recommendation for the Industry Linkage

 If the linkage builds good relationship with the industries and factories in the
country, they may willingly accept more students. This will reduce the tiredness
of the student for searching a factory to spend their internship period. So the
industry linkage should strengthen relations with factories and industries

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References
[1] National Cement Share Company manual, 2018
[2] Collected data from the company by asking electricians and operators
[3] W. Bolton, “Programmable Logic Controllers”, Elsevier Newnes, Fourth Edition, 2006
[4] Hans-Petter Halvorsen, “SCADA Systems”,
[5] Stephen J. Chapman, “electric machinery fundamentals” McGraw-Hill, Fourth Edition, 2005
[6]Jon S. Wilson, ”Sensor Technology Handbook”, Elsevier Inc, 2005

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BAHIR DAR UNIVERSITY

BAHIR DAR INSTITUTE OF TECHNOLOGY

FACULITY OF ELECTRICAL AND COMPUTER ENGINEERING

DEPARTMENT OF ELECTRICAL ENGINEERING

STREAM: INDUSTRIAL CONTROL

HOSTING COMPANY: NATIONAL CEMENT SHARE COMPANY

(DIRE DAWA PLANT)

NAME OF INTERNS ID. NO.

Name of Advisor Signature Date

Name of Internees Signature Date

Internship report on NCSC Page ii

Internship report on NCSC Page iii

Internship report on NCSC Page iv

Internship report on NCSC Page v

Internship report on NCSC Page vi

Internship report on NCSC Page vii

Internship report on NCSC Page viii

Internship report on NCSC Page ix

Figure 1.1 Bird eye view of NCSC

Internship report on NCSC Page 1

1.2 Vision, mission and objective of the company

 To be the preferred supplier of quality cement in the continent

1.2.3 Objective of the company

Internship report on NCSC Page 2

1.3 Organizational structure of the Company

Internship report on NCSC Page 3

1.3.1 Task of each section

Internship report on NCSC Page 4

Internship report on NCSC Page 5

1.4 Key Stake Holders of the Company

1.5 Production process in national cement

1.5.1 Production Process

Raw mix silos grinded raw mix silos

Figure1.3 Production process

Internship report on NCSC Page 6

Internship report on NCSC Page 7

Internship report on NCSC Page 8

2.1.1 General Objective

Some of the general objective of internship includes:

2.1.2 Specific Objectives

The specific objectives of this internship are:

Internship report on NCSC Page 9

A. Crusher area B. Kiln area

Internship report on NCSC Page 10

2.4 Overall System Components and Operations

Internship report on NCSC Page 11

Internship report on NCSC Page 12

Figure 2.2 Gypsum crusher

 Power cable rotating drum and

Internship report on NCSC Page 13

Figure 2.3 Stacker

Internship report on NCSC Page 14

Figure 2. 4 (A) Bridge scraper reclaimer (B) Side scraper reclaimers

bag filters), rotary motor etc.

Internship report on NCSC Page 15

purged dust and particles so as to drop it into the belt conveyer.

compartment is clean normal filtering resumes.

The main uses of bag filter is

 Separation of gas from material

 Protection of the environment

Internship report on NCSC Page 16

Figure 2.5 Bag filter