Haramaya University Haramaya Institute of Technolgy School of Electrical and Computer Engineering

HARAMAYA UNIVERSITY
HARAMAYA INSTITUTE OF TECHNOLGY

SCHOOL OF ELECTRICAL AND COMPUTER ENGINEERING
POWER STREAM
FINAL INTERNSHIP REPORT
HOSTING COMPANY: NATIONAL CEMENT SHARE COMPANY
DIRE DAWA (NCSC)
PREPARED BY:
NAME ID NO
ASHENAFI TURI………………………………………………. R/0323/09

DERIBE TEFERA……………………………………………R/0519/09
DURATION OF INTERNSHIP: JUNE 15/2021– AUGUST 06/2021

SUBMISSION DATE: 25 AUGUST 2021
INTERNSHIP REPORT 2021
DECLARATION
We want to assured that this report exactly 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 students: Signature: Date:

Ashenafi Turi --------------------- ------------------
Deribe Tefera --------------------- -------------------
Approval of advisors Signature: Date:
Mr. Gechanu.A -------------------- ----------------------
Approval of company supervisor Signature: Date:
Mr. Abay Firew -------------------- ----------------------
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ACKNOWLEDGMENT
First of all, we would like to thanks our GOD, the most beneficent and merciful. We are very
happy to avail this golden opportunity of getting training at national cement share company, and
we would like to grateful and thankful to the HARAMAYA INSITUTE OF TECHNOLOGY,
especially school of electrical and computer engineering that provided me this golden chance to
explore my skills, qualities, abilities and potentials through internship program and also, thanks
for all managers and employers of National cement share company specially ENG.Gebrehiwet
who is production manager of NCSC, ENG. Deseye, ENG. Melaku, ENG. Abay, ENG.
Mohamed, ENG. Khalid for their admired patient and genuine intention to teach us under great
motivation. Our advisor, Mr. Gechanu.A for his visiting and advising us in doing of our report.
In general, this report is a result of hand work of not a single person but a many persons have
added their volunteer services and their kindness to improve this report.
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EXECUTIVE SUMMARY
This document consists of the internship report that we have performed in the internship program
from June beginning to August beginning, 2021 G.C. It includes the background and overall
organization of our internship hosting company. The report includes our overall internship
experience, benefits and the challenges that we have been faced and the measures we have taken
to overcome those challenges and recommendations. Generally, the internship has helped us to
develop good social and communicational skills. We develop knowledge on how to
communicate with different class of employees (with the engineers, technicians and workers
from other department). The main raw material of the company and the role of each device found
in the company, like the main motors, protection of motors, transformer, PLC and sensors. The
report has written according to the given guidelines, and has everything about our internship
experience.
Key words: - PLC
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Table of Contents
DECLARATION ................................................................................................................................................ i
ACKNOWLEDGMENT ..................................................................................................................................... ii
EXECUTIVE SUMMARY ................................................................................................................................. iii
List of Figure ................................................................................................................................................. vi
List of Table ................................................................................................................................................. vii
List of Acronyms ......................................................................................................................................... viii
CHAPTER ONE ............................................................................................................................................... 1
1. BACKGROUND OF THE NATIONAL CEMENT SHARE COMPANY ............................................................ 1
1.1 Brief History of the Hosting Company ................................................................................................ 1
1.1.1 Mission ......................................................................................................................................... 2
1.1.2 Vision............................................................................................................................................ 2
1.1.3 Values ........................................................................................................................................... 2
1.2 Main Products of the Cement Company............................................................................................. 3
1.2.1 Ordinary Portland cement (OPC) ................................................................................................. 3
1.2.2 Portland Pozzolana Cement (PPC) ............................................................................................... 4
1.3 Main Customers of the Company ....................................................................................................... 5
1.4 Overall Organization and Work Flow .................................................................................................. 6
1.5 Work Flow of the Company’s Production ........................................................................................... 7
CHAPTER TWO ............................................................................................................................................ 15
2. OVERALL INTERNSHIP EXPERIENCE..................................................................................................... 15
2.1 Section of the Company .................................................................................................................... 15
2.2 Work Piece or Work Tasks ................................................................................................................ 16
2.3 Techniques of Controlling and Protection Mechanism .................................................................... 17
2.3.1 Instrumentation (control) section.............................................................................................. 18
2.3.2 Types of sensor in the factory .................................................................................................... 18
2.3.3 Control device ............................................................................................................................ 23
2.3.4 Plant operation control system.................................................................................................. 26
2.4 Electrical (Power) Section ................................................................................................................. 28
2.4.1 Motor starting and protection methods .................................................................................... 28
2.5 Safety Mechanisms in Motor Starting Method ................................................................................ 35
2.6 Motor Winding Section ..................................................................................................................... 36
2.7 Types of Winding ........................................................................................................................ 37
2.8 Substation ......................................................................................................................................... 37
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2.8.1 Isolator ....................................................................................................................................... 38

2.8.2 Main circuit breaker (sf6) ........................................................................................................... 38
2.8.3 Current transformer (CT) ........................................................................................................... 39
2.8.4 Voltage transformer (VT) ........................................................................................................... 39
2.8.5 Power transformer (PT) ............................................................................................................. 39
2.8.6 Surge arrester ............................................................................................................................ 40
2.8.7 Power factor............................................................................................................................... 40
2.9 Major Challenges & Problems in Internship ..................................................................................... 41
2.10 Measures and Recommended the Problems & Challenges ............................................................ 42
CHAPTER THREE .......................................................................................................................................... 44
3. PROFITS WE GAINED FROM THE OVERALL INTERNSHIP EXPERIENCE ................................................ 44
3.1 Upgrading Our Theoretical Knowledge:............................................................................................ 44
3.2 Improving Our Practical Skills ........................................................................................................... 45
3.3 Improving Our Team Playing Skills .................................................................................................... 45
3.4 Improving Our Leadership Skills:....................................................................................................... 46
3.5 Understanding about Work Ethics Issues and Industrial Psychology ............................................... 47
3.6 Entrepreneurship Skills: .................................................................................................................... 49
3.7 Improving Our Interpersonal Communication Skills: ........................................................................ 49
CHAPTER FOUR ........................................................................................................................................... 51
4. CONCLUSION AND RECOMMENDATION ............................................................................................ 51
4.1 Conclusion ......................................................................................................................................... 51
4.2 Recommendation.............................................................................................................................. 52
4.2.1 Recommendation to the Company ............................................................................................ 52
4.2.2 Recommendation to the University ........................................................................................... 52
REFERENCES ................................................................................................................................................ 53
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List of Figure
Figure 1: National Cement Entry ............................................................................................................................ 2
Figure 2: Products of National Cement, OPC .......................................................................................................... 4
Figure 3: Products of National Cement, PPC ........................................................................................................... 5
Figure 4: Quarry, raw material blasting area ......................................................................................................... 7
Figure 5: Raw material crusher area ...................................................................................................................... 8
Figure 6: Pre-homogenization and blending area .................................................................................................. 8
Figure 7: Proportion silos ....................................................................................................................................... 9
Figure 8: Vertical Roller Mill................................................................................................................................. 10
Figure 9: Bag house and Homogenization silo ...................................................................................................... 10
Figure 10: Pre heater ........................................................................................................................................... 11
Figure 11: Rotary kiln ........................................................................................................................................... 11
Figure 12: Clinker silo and Cement grinding mill .................................................................................................. 13
Figure 13: Cement silos ........................................................................................................................................ 14
Figure 14: Rotary packer ...................................................................................................................................... 14
Figure 15: Inductive sensor .................................................................................................................................. 18
Figure 16: Thermocouple ..................................................................................................................................... 19
Figure 17: Level sensor ......................................................................................................................................... 20
Figure 18: Load cell .............................................................................................................................................. 21
Figure 19: Gas Analyzer ....................................................................................................................................... 23
Figure 20: Vacuum circuit breaker ....................................................................................................................... 24
Figure 21: Solid relay ........................................................................................................................................... 25
Figure 22: Limit switch ......................................................................................................................................... 25
Figure 23: Central control room ........................................................................................................................... 27
Figure 24: Direct online starting ........................................................................................................................... 29
Figure 25: Forward reversing starting method ..................................................................................................... 30
Figure 26: Star delta starting method .................................................................................................................. 31
Figure 27: Liquid resistor starter (LRS) ................................................................................................................. 32
Figure 28: Soft starter .......................................................................................................................................... 33
Figure 29: Variable frequency drive .................................................................................................................... 34
Figure 30: Main substation ................................................................................................................................. 38
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List of Table
Table 1: Different types of motor control system in national cement………………………………….35
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List of Acronyms
NCSC National Cement Share Company
PLC Programmable logic controller
DOL Direct on-line
VRM Vertical raw mill
VCM Vertical coal mill
LV Low voltage
DC Direct current
AC Alternating current
LRS Liquid resistor starter
VFD Variable frequency drive
KM1 Star contactor
KM2 Delta contactor
KM3 Main contactor
K1T Timer
KT Timer coil
KT3 Time delay auxiliary contactor
NO Normally open
NC Normally close
OPC Ordinary Portland cement
PPC Portland Pozzolana cement
U1, V1, W1 Primary terminal of motor
U2, V2, W2 Secondary terminal of motor
PLC Programming logic control
GC Gregorian calendar
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CHAPTER ONE
1. BACKGROUND OF THE NATIONAL CEMENT SHARE COMPANY

1.1 Brief History of the Hosting Company
The Cement industry is a well-established manufacturing industry dating back to the Greek and
Roman Empires where cement was used in structures over 2000 years ago. The modern cement
industry dates back to the 1800s.In Ethiopia, Italians established a cement factory in 1936 during
the five years’ fascist occupation of the country. National Cement Share Company is located in
the Eastern part of Ethiopia, right at the entrance of Dire Dawa city at 515 km away from the
capital city of Addis Ababa and it is the first factory established in the Ethiopia. Now a day there
are around 20 cement companies engaged in production of cement. The installed production
capacity had reached 11.2 million tons. This is expected to further increase to 17.5 million tons.
The factories are actually producing 5.47 million tons per annum.
The new National Cement Share Company was established in November 2005 through a joint
venture of East African Mining Corporation, the Federal Government of Ethiopia’s Privatization
& Public Enterprises Supervising Agency and others. Over the next few years, government
shares were bought out by East African Mining Corporation. Now the company is privately
owned share company.
After building the new cement factory, the company has boosted the production from 150 tons
per day to 400 tons per day, then after successive expansions made by the company is currently
producing 3000 tons’ clinker, or 80,000 bags of cement, per day [7].
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Figure 1: National Cement Entry
1.1.1 Mission
To produce & distribute cement products that exceedingly meets customer requirements, by
adopting modern technology, qualified manpower and by ensuring eco-friendly and socially
accountable operation and thereby creating sustainable value for our stakeholders. We are
committed to delivering value for our customers, safe and empowering environment for our
employees, and superior returns to our shareholders [7].
1.1.2 Vision
To become the leading cement manufacture in the country and become exemplary in boosting
derived privately owned businesses in the region and in the country at large. To be the preferred
supplier of building materials in the region [7].
1.1.3 Values
 Leadership - encourage innovation and empowerment.
 Focus - pursue focused strategies that create competitive advantages.
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 Commitment - provide customers with better value and services
 Performance – deliver the highest quality products to our customers.
 Sustainability – build enduring partnerships with customers and suppliers.
 Integrity – ensure all business dealings are ethical and transparent.
1.2 Main Products of the Cement Company

Cement is an inorganic, non-metallic, finely ground substance which, after mixing with water,
sets and hardens independently as a result of chemical reactions with the mixing water and, after
hardening, it remains its strength and stability even under water. The most important area of
application is therefore the production of mortar and concrete, i.e., the bonding of natural or
artificial aggregates to form a strong building material which is durable in the face of normal
environmental effects. National Cement SC is a cement manufacturing industry. Its main
products, types of cement, are listed and explained below:
1.2.1 Ordinary Portland cement (OPC)

This is by far the most common cement used in general concrete construction when there is no
exposure to sulphates in the soil or in ground water. Ordinary Portland cement is the cement
most widely used. Moreover, using highly early strength cement for a given specified 28 days’
strength of concrete, it is possible to use a leaner mix, with higher water/ cement ratio. Some of
these mixes have an inadequate durability.
This type of cement is produced from 95% clinker (produced by basalt, limestone& clay
materials) and 5% Gypsum additive ingredient.
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Figure 2: Products of National Cement, OPC
1.2.2 Portland Pozzolana Cement (PPC)

Contain up to 35% fly ash. The fly ash is Pozzolana, so that ultimate strength is maintained.
Because fly ash addition allows lower concrete water content, early strength can also be
maintained. Where good quality cheap fly ash is available, this can be an economic alternative to
ordinary Portland cement. As a rule, Portland Pozzolana Cements gain strength slowly and
therefore require curing over a comparatively long period, but the long term strength is high
shows that similar behavior occurs where the Pozzolana replaces part of cement, but the long-
term strength depends on the level of replacement.
This type of cement is produced by mixing 65% clinker and additive of Gypsum and Pumice.
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Figure 3: Products of National Cement, PPC
1.3 Main Customers of the Company

The major customers of the company are, those customers who are in need of mainly cement and
clinker, those include:
Building and road construction contractors
 Concrete products manufacturers
 Retail shops
 Growing domestic construction industry
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1.4 Overall Organization and Work Flow
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1.5 Work Flow of the Company’s Production

The cement industry is a huge industry; it is composed of many big types of machinery which
are used for the manufacturing of cement starting to the raw material preparation up to
cement packing. The production process of cement is long. The following article will discuss this
production in detail using images.
1. The quarry is the starting point. Cement plants are usually located closely either to hot
spots in the market or to areas with sufficient quantities of raw materials. The aim is to
keep transportation costs low. Basic constituents for cement (limestone and clay) are
taken from quarries in these areas. Mining the raw materials Limestone, Pumice, Basalt is
blasted from rock quarries mostly by setting off explosives with a negligible impact on
the environment.
Figure 4: Quarry, raw material blasting area
The blasted & fragmented raw materials then transported to the crushing area, using dump
trucks. The transported quarry raw material is then delivered through chutes to the crushers,
where its size is reduced by crushing or pounding to chunks approximately 10 to 20mm in size
(for limestone). There are different types of crashers to crush those different raw materials
(limestone crasher, coal crasher, gypsum crasher& pumice crusher).
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Figure 5: Raw material crusher area
2. Prehomogenization the next process. In cement production, it is often necessary to

prehomogenize the raw materials after secondary crushing, particularly when their
chemical and mineralogical composition varies over a wide range. This unit operation is
utilized primarily for the main raw materials, viz., the limestone and the aluminosilicate
component. Prehomogenization is the proportional mix of the different types of clay,
limestone, or any other required material.
Figure 6: Pre-homogenization and blending area
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3. Proportioning raw material. This process is done after the materials are put into a storage
in which each of the raw materials are transported separately to the proportion silos,
where the raw materials later will be added in specific amounts to the Vertical Roller Mill
according to the particular type of cement being produced.
Figure 7: Proportion silos
4. Raw material mill. This process takes places using Vertical Roller Mill (VRM), in which
the proportioned material from the proportion silo will enter to the VRM, which grinds
the material through the pressure exerted by three conical rollers which roll over a turning
milling table. Then the grinded fine raw mixture is sucked by the use of suction fan.
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Figure 8: Vertical Roller Mill
The sucked fine raw material from the VRM will be trapped inside the Bag house, which then be
transported to Homogenization Silo by air slide and bucket elevator conveying system. Then raw
homogenization process takes place in silos equipped for obtaining a homogenous mix of the material.
Figure 9: Bag house and Homogenization silo

5. After the material is homogenized it then be transported to pre heater for calcinations
process. Calcination is a process of calcining - heating a substance to a high temperature,
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but below its melting point, to bring about thermal decomposition. In the preheated
section the material is heated at high temperatures and it’s to then reach about 1000oC.
The heating process is not complete yet; the high temperature degree raw material then
enters to a Rotary Kiln. Inside the rotary kiln the raw material is transformed into clinker,
by heating it at 1400oC: clinker is small, dark gray nodules 3-4 centimeters in diameter.
Figure 10: Pre heater
The heating process is not complete yet; the high to raw material then enters to a Rotary Kilns.
Inside the rotary kiln the raw material is transformed into clinker, by heating it at 1400Oc.
Figure 11: Rotary kiln
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6. Clinker leaves from the outlet end of the kiln (pre-cooling zone) at a temperature of 1200
C ̊ -1250 C ̊ entering to cooler. The hot clinker was dumped in the open storage yard for
cooling. The cooler using 3 fans to cooling. The purpose of cooling is not only to cool the
clinker, but also to recuperate heat and return into the kiln in the form of secondary to
keep the overall kiln fuel consumption to a minimum. The clinker leaving the cooler
should be cool enough to avoid damage to handling by deep bucket conveyor (DBC).
Cooled clinker can also be beneficial to cement mill efficiency by reducing the possibility
of overheating. They are different types of cooler, but NCSC uses great cooler type.
Great cooler is cross flow heat exchange through clinker bed with cold air. The clinker
cooler cools the hot granular mass of clinker by quenching air into it bringing the
temperature down to 100ºC. Conveyors (by chain conveyor) transport then the cooled
clinker to the clinker silo.
Figure 12: Great cooler
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7. After the clinker is stored in big silos, it then transported to a cement grinding mill
(Figure. 12), which may be located in different place to the clinker plant. Gypsum
(calcium sulphates) and possibly additional cementations (such as blast furnace slag, coal
fly ash, natural Pozzolana, etc.) or inert materials (limestone) are added to the clinker. All
constituents are ground leading to a fine and homogenous powder. The cement is then
stored in silos before being dispatched either in bulk or bagged.
Figure 12: Clinker silo and Cement grinding mill
8. The grinded cement from the cement mill is then housed in storage silos. There are four
storage silos in our company which are used to store OPC and PPC in different silos.
From where it is hydraulically or mechanically extracted and transported to where it will
be packaged in sacks or supplied in bulk. In either case, it can be shipped by rail car,
freighter truck.
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Figure 13: Cement silos
There is rotary packing mechanism in the packing there are two proximity sensors one for
starting the motor and feed the sacks and the other one to off the motor and left the sack to the
transport belt. And there is PLC controllers which have an input of load cell and weight range of
45-60kg feedback which sated at 50 kg.
Figure 14: Rotary packer
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CHAPTER TWO
2. OVERALL INTERNSHIP EXPERIENCE

Internship programs are educational programs which give opportunities for students to explore
new things and help them know what is there in the real world. It also helps the candidates to
change their theoretical knowledge into more practical experience. This program is a best ground
for trainers or students to make them able to be fit in numerous problem solving areas which
need a skilled man power with more practical knowledge not only theoretical knowledge.
And us, we had been exploring new machineries that we haven’t learnt before, and to have many
opportunities to be practically a bled student. During the internship, we are expected to improve
our practical, theoretical, interpersonal communications, team playing, entrepreneurship and
leader ship skills, understanding about work ethics related issues and responsibility, and also to
observe a certain problems and suggest recommendations and propose a project on it.
2.1 Section of the Company

In the National Cement we are working in engineering department and this department has three
main working sections which work their separate functions, those sections are listed and
explained as below.
1. Instrumentation section: this section of engineering department concerns with

maintenance and installation of compressors, bag filters, oil stations, oil pumps and etc…
they are basically thermal sections of the engineering department.
2. Maintenance section: this is the main section of the department, as its name indicates; it
is a section dealing with maintenance of all of the company’s machines starting from the
big ones to the small ones, apart from the utility department maintenances. It has sub
sections in areas for division of work and responsibility, in the following way:
 Crusher area maintenance unit

 VRM and kiln area maintenance unit
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 Cement mill and packing area maintenance unit.
3. Workshop section: this section of electrical department concerns with re-winding of

motors, changing of bearings and other parts of motors that needs to be changed and
etc…Through our internship period in the company we were separated in groups with
other university students and assigned in those sections for specified period of time. In
our internship we have been working, supporting and viewing (for those difficult tasks
that we can’t perform alone) and gathered more information and experience from the
workers of those sections.
2.2 Work Piece or Work Tasks

In the engineering department of the company specific work is given to the responsible section
of the department, for example work regarding heat exchangers, compressors, and oil stations are
given to the utility section and the like. As we were discussing in the previous topic there are
different sections of engineering, and we, as an electrical engineering student, have been working
in those main sections of the company.
In our two months’ period of internship, we are working in different section depending up on
our theoretical knowledge and our experience we have before, in order to develop our
practical knowledge by guided by company supervisors. As we are electrical engineering we
are working in the engineering department within our related course. For those two months
we are working on inspection of each motors found in
 Crusher area
 Cement Mill and packing area
 Kiln, VRM and VCM area
1. Crusher area inspection activities
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In this area there are crushers for grinding raw materials, which are limestone & basalt crusher,
coal crusher, and gypsum & rhyolite crusher. This area also contains machines for pre-
homogenization and blending processes, which are bridge declaimers and suspended boom
stalkers.
On those machineries there were different motors are used to running the process of crushing the
raw material such as rock, claim, and other materials.
2. Cement mill and packing area inspection activities
Those three areas are the last areas of the cement production in the company. After finishing the
crusher area our company supervisor has assigned us to work around this area to check their
motor for different types of machines available at this area. Those machines are very huge
especially the rotary kiln which is used to heat and melt the grinded raw materials to high
temperature.
3. Kiln, VRM (Vertical Roller Mill) and VCM (Vertical Coal Mill) area inspection
activities
These two huge machineries are also known by the company’s workers as the two kidneys of the
company. They have given this name to them because the company will not run production of
cement if they are not operating in a healthy manner. So inspection of motors and maintenance
processes in those areas take serious attentions and high level of manpower especially skilled
workers or engineers. After kiln, cement mill and packing area we are working on this station for
checking of their motors. For our half of internship time we are working on inspection of the
motors for each area as we are describing above.
2.3 Techniques of Controlling and Protection Mechanism
For the second round after finishing the inspection we are working and observing the overall
mechanisms of national company’s controlling, starting, protection, and rewinding process and
understand all process.
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2.3.1 Instrumentation (control) section

Instrumentation section includes all the controlling devices that are applied on the factory system
such as; temperature sensor, level sensor, speed sensor, emergency switches, gas analyzer, etc.
we have tried to describe some of them as follows;
2.3.2 Types of sensor in the factory


 Inductive sensor
 Capacitive sensor
 Temperature sensor
 Level sensor
 Speed sensor
 Pressure transmitter
 Load cell
 Gas analyzer
a. Inductive sensor: -is an electronic proximity sensor which detects metallic objects without
touching them. In NCSC there is in belt conveyor of non-drive end and bucket elevator.
b. Capacitive sensor: - is also an electronic proximity sensor which detects metallic object by
touching them. In NCSC there is in kill area cooler system for hydraulic system.
Figure 15: Inductive sensor
c. Temperature sensor: - an analog temperature sensor is pretty easy to explain it’s a chip
that tells you what the ambient temperature. There is k-type temperature sensor in NCSC.
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There are some of temperature sensors in NCSC:

 Thermocouple: -thermocouple is one type of temperature sensor it’s a
combination of two wires which have different electrical properties. The two
wires are joined at both ends so we will have 2 junctions. When we bring it to
work one junction is made hot and the other is cold and then the difference in
temperature brings a small current. This thermocouple specially used for high
temperature (>400) degree centigrade.
Thermocouple application in cement industry: -

 At pre-heater
 For measuring gas and material temperature
 At clinker cooler
Generally, where high temperature operation required
Figure 16: Thermocouple
 Resistance temperature detector (RTD):- RTD is made from high purity

conducting metal such as platinum, copper or nickel wound into a coil. The RTD
is a temperature sensor based on the fact that metal increase in the resistance as
temperature rise. RTDs are passive resistive devise and by passing a constant
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current through them, they produce output voltage that increase linearly with
temperature.
 Bearing temperature
 Winding temperature of big motors
 Low temperature process parameter
 LRS
 Thermistor: - this instrument is somehow similar to RTDs their difference is that

the material used in RTD is a metal but in case of thermistor we use ceramic. And
also RTDs used in high temperature ranges and thermistor in lower ranges.
Thermistor work, the temperature is high when the resistance is low and vice
versa.
d. Level sensor: -level sensor detects level of substance that flow including liquids, slurries,
granular material and powders. Fluids fluidized solids flow to become essential level in
their container or other physical boundaries because of gravity whereas most bulk solids
pile at an angle of response to a peak. The level measurement can be either continuous or
point values. Continuous level sensor measure level within a specified range and
determine the exact amount of substance in certain place, while point-level sensor only
indicate whether the substance is above or below the sensing point. Generally, the latter
detect levels that are excessively high or low.
Figure 17: Level sensor
In NCSC this level sensor is most often used in raw mill and cement silos. Up on the indication
of these sensors the diverters of the silos will change the way of the feed of the silos.
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e. Speed sensor: - Speed sensor is widely used for measuring the output speed of a rotating
object. There are many types using different principle and most of them produce an
electrical output.
 Tachometer: -There are two types, AC, and DC. The AC type generates a
sinusoidal output. The frequency of the voltage represents the speed of rotation.
The frequency must be counted and processed. The DC type generates a voltage
directly proportional to the speed. Both types must be coupled to the rotating
body. Very often the tachometer is built into electric motor to measure their
speed.
f. Pressure transmitter: - This is a device which senses the pressure and accordingly
transmit electrical signal in the form of current. Normally it is powered with 24v dc and
its current varies between 4 ~ 20 mA with respect to pressure. Pressure transmitters are
available in different ranges. Depending up on the range, it can be calibrated accordingly.
For example: If a pressure transmitter range is 0 ~ 10 bar Then at 0 bar it will give 4 mA
and at 10 bar it will transmit 20 mA.
g. Load cell: -Load cell is a sensor which is used for measurement of weight. It is
connected to weighing indicator for display of load. Depending upon capacity, load cells
are available in different weighing ranges.
Figure 18: Load cell

Figure 19: Load cell
h. Gas Analyzer: the gas analyzer system is all about measuring the amount of each gas
inside the KILN to get a good heat (fire). It used to mix the gasses and control the needed
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amount of each gas. And the gasses are measured through the sample taking pipe. The
gasses inside the kiln are
 NO (nitrogen monoxide): we measured NO to know the final temperature of
the kiln, whether it’s good or not. When the NO inside the kiln becomes
higher and higher, the temperature becomes good.
 CO (carbon monoxide)
 O2 (oxygen)
Here the sample taken through the pipe needs to be cooled, b/c it has a hot temperature. Some
parts of the system are;
Cooling system of the sample taking pipe:- The pipe has two tubes inside; the sample taking
tube and the oil tube so here the cooling system done by oil.
How it operates?
Its operation is a circulation type (which is rotation). The oil gets into the pipe and cools the hot
sample and gets back into the refrigerator (to make it cool) and it repeats this flow again and
again.
 Flow sensor: The flow of the oil is controlled by flow sensor which has an indicator
on it.
 Level indicator: indicates the amount of oil we have in the tanker.
 Thermocouple (temperature sensor): sense the temperature of the oil.
 Fan: is used when temperature of the oil becomes higher. It does not work in all
times; it works only when the temperature gets higher.
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Figure 19: Gas Analyzer
2.3.3 Control device

Every control circuit is composed of a number of basic components connected together to
achieve the desired performance. The size of the components varies with the power of the motor,
but the principle of operation remains the same. The basic components are the following:
 Air, vacuum, SF6 circuit breakers
 Pushbuttons, selectors
 Solid Relays
 Limit switches, rope switches and drift switches
 Resistors, reactors, transformers, and capacitors
 Vacuum circuit breaker: In this breaker vacuum is used as the arc quenching medium.
Vacuum offers the highest insulation strength. So it has far superior arc quenching
properties than any other medium. For example, when contacts building up at a rate
thousands of times higher than that obtained with other circuit breakers. It is suitable for
mainly medium voltage application. The operation is as follow:
When the contacts of the breakers are opened in vacuum, an arc is produced between the
contacts by the ionization of metal vapors of contacts. However, the arc is quickly extinguished
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because the metallic vapors, electrons and ions produced during arc rapidly condense on the
surface of the circuit breaker contacts, resulting in quick recovery of dielectric strength.
The salient feature of vacuum as an arc quenching medium is that as soon as the arc is produced
in vacuum, it is quickly extinguished due to the fast rate of recovery of dielectric strength in
vacuum.
Figure 20: Vacuum circuit breaker
Push buttons: Are a switch activated by finger pressure. Two or more contacts open or close
when the button is depressed. Pushbuttons are usually spring loaded so as to return to their
normal position when pressure is removed.
 Solid relay: The Solid State Relay provides a high degree of reliability, long life and
reduced electromagnetic interference (EMI), (no arcing contacts or magnetic fields),
together with a much faster almost instant response time, as compared to the conventional
electromechanical relay.
Also the input control power requirements of the solid state relay are generally low enough to
make them compatible with most IC logic families without the needfor additional buffers, drivers
or amplifiers. However, being a semiconductor device they must be mounted onto suitable heat
sinks to prevent the output switching semiconductor device from overheating.
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Figure 21: Solid relay
 Limit switch: Is a low- power snap-action device that opens or closes a contact,
depending up on the position of a mechanical part. Other limit switches are sensitive to
pressure, temperature, liquid level, direction of rotation, and so on.
Figure 22: Limit switch
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 Emergency switches
Pull rope switch: - Pull rope switches provide a system to isolate the power to conveyor
system and other process equipment in event of an emergency. Pull rope switches are actuated by
a plastic coated steel wire rope placed along-side the conveyor. Pulling on the rope at any point
Drift switch: - like pull rope switch it provide a system to isolate the power to conveyor system
and turning of the belt from the conveyor frame will trip and automatically lock the switches, de-
energizing the conveyor starts contactor.
2.3.4 Plant operation control system

All plant control from central control room (CCR), all operation monitors from CCR using
computer by sematic PCS7 programmable logic control (PLC) with window control center for
graphic display. For faster communication the data transmission user optical fiber
communication system and for enter connection of S7-300 and S7-400 used to cable.
 Hardware part of sematic S7
 Rack or buss (for inter connection)
 Power supply
 CPU (central processing unit)
 Input module
 CP (communication process)
 IM (interfacing module)
 Network architecture of national cement
In national cement network architecture consist of four master S7-400 CPUs kiln outlet kiln
inlet, row mill and cement mill. Each of them have own CP (communication process module)
and IM (interfacing module).
Those network is used as communication media throw industrial Ethernet switch (IES),all CPU
inter connected in loop with CP and IES, the switch also used to convert electrical data into
optical data system then the data transfer into DCS (distance control station) receved by another
industrial Ethernet switch the convert optical data into electrical data.
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For expansion of the network or to add new machine in plant used IM(interface module) also
expansion of input module output module used IM module.
Central processing unit (CPU) inter connected by communication processor (CP) module threw
rack or bus for inter connection of IM with CP used DP cable.
CP inter connected with industrial Ethernet switch connected by optical fiber cable then the data
transfer into server room from server room to server and slave computer transfer data by coaxial
cable.
In DCS there is one server computer in engineering station to modification and programming
also in central control room (CCR) 6 operation station computers for operation purpose or only
for run time control.
Figure 23: Central control room
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2.4 Electrical (Power) Section

Based on our understanding, this section deals such things like; power system, motor system
(motor starting methods, motor windings, motor control). Generally, all power centered topics
starting from the substation.
2.4.1 Motor starting and protection methods

As we have observed, in NCSC almost all the motor is AC type motor which are either slip ring
motor (6kv) or squirrel cage motor. But there is also one DC motor at kiln area. In the company
the DC motor are not available because they are too costly and not easy for maintenance to AC
motors.
 Starting methods
When motor is switched on, there is a high inrush current from the mains which may cause damage,
especially if the power li e section is inadequate voltage likely to affect receptor operation. This drop
may be severe enough to be noticeable in lighting equipment. To overcome this, some sector rules
prohibit the use of motors with direct on-line starting system beyond a given power. There is several
starting system which differ according to the motor load specification. The choice is governed by
electrical, mechanical and economic factors.
The kind of load driven is also important in the choice of starting system.
 There are five different motor starting methods
 Direct on-line start (DOL)
 Forward reverse start
 Start-delta start
 Frequency converter
 Soft starter
 Liquid resistance starter(LRS)
1. Direct on-line starter (DOL)
 This is the simplest mode for motor starting, and this mode has the following
components;
 Circuit breaker
 Electromagnetic contactor
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 Overload relay
 Push buttons
 The power of the motor is low compared to that of the mains, which limits interference
from inrush current.
 The machine to drive does not need to speed up gradually nor has a damping device to
limit the shock of starting.
 The starting torque can be high without affecting machine operation
Figure 24: Direct online starting
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2. Forward reversing motor

The forward reverse motor control is used in a system where forward and backward or upward
and downward movements in the operation are needed. Forward and Reverse Operation of motor
can be obtained by interchanging any two of its three terminals.
 Function and operation
In the Circuit both the Forward & Reverse Contactor interlocked in a way that only one contactor
should be in closed condition whiles the other is in open condition.
Figure 25: Forward reversing starting method
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3. Star-delta starting
The objective of this starting method, which is used with three-phase induction motors, is to reduce
the starting current. In starting position, current supply to the stator winding is connected in star(Y)
for starting. In the running position, current supply is reconnected to the winding in delta one the
motor has gained speed normally low voltage motors over 3KW will be dimensioned to run at either
400V in delta connection or at 690V in star Y connection. The flexibility provided by this design can
also be used to start the motor with a lower voltage. Star delta connections give a low starting current
of only about one third of that found with direct-on-line starting. Star-delta starters are particularly
suited for high inertias, where the loads are initiated after full load speed.
Figure 26: Star delta starting method
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4. Liquid resistor starter (LRS)

Some motors like slip ring motors, cannot be started direct on line with its rotor windings short-
circuited, otherwise it would cause unacceptable current peaks. Resistors must therefore be
inserted in the rotor circuit and then gradually short-circuited, while the stator is powered at full
mains voltage. The resistance (soda ash) inserted in each phase is calculated to ascertain the
torque-speed curve with strict accuracy. The result is that it has to be fully inserted on starting
and that full speed is reached when it is completely short-circuited.
The current absorbed is more or less proportional to the torque supplied at the most only a little
greater than theoretical value.
How liquid resistor works?
Combination of water and caustic soda for improving the resistance in starter is called Liquid
Resistance Starter. If any slip ring induction motor, at the time of starting given the external
resistance required to rotor side, why because starting current and starting torque is very high.
Liquid starter consist of
 Motor pole plate which is work on forward and reverse direction
 Movable bus bars
 Electrolytic solution (soda ash)
 Solution level sensor
 Temperature sensor
 Limit switch
Figure 27: Liquid resistor starter (LRS)

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5. Soft starter
A motor soft starter is a device used with AC electrical motors to temporarily reduce the load
and torque in the power train and electric current surge of the motor during start-up. A soft
starter continuously controls the three-phase motor’s voltage supply during the start-up phase.
This way, the motor is adjusted to the machine’s load behavior. Mechanical operating equipment
is accelerated smoothly. Service life, operating behavior and work flows are positively
influenced. Electrical soft starters can use solid state devices to control the current flow and
therefore the voltage applied to the motor. They can be connected in series with the line voltage
applied to the motor, or can be connected inside the delta (Δ) loop of a delta-connected motor,
controlling the voltage applied to each winding. Solid state soft starters can control one or more
phases of the voltage applied to the induction motor with the best results achieved by three-phase
control. Typically, the voltage is controlled by reverse-parallel-connected silicon-controlled
rectifiers (thyristors), but in some circumstances with three-phase control, the control elements
can be a reverse-parallel-connected SCR and diode.
Figure 28: Soft starter
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6. Variable frequency drive

A variable-frequency drive (VFD) (also termed adjustable-frequency drive, variable-speed drive,
AC drive, micro drive or inverter drive) is a type of adjustable-speed drive used in
electromechanical drive systems to control AC motor speed and torque by varying motor input
frequency and voltage. The AC electric motor used in a VFD system is usually three-phase
induction motor. Some types of single-phase motors can be used, but three-phase motors are
usually preferred. Various types of synchronous motors offer advantages in some situations, but
three-phase induction motors are suitable for most purposes and are generally the most
economical motor choice. Motors that are designed for fixed-speed operation are often used.
Elevated-voltage stresses imposed on induction motors that are supplied by VFDs require that
such motors be designed for definite-purpose inverter-fed duty.
Figure 29: Variable frequency drive
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Name of control Working area Advantage of control

system system
Direct online control system In bag filter, oil station etc. It reduces cost simple
starting system used for
small motor
Star delta control system Air compressor It reduce current when

starting time used for
above 15KW motor
Soft starter starting system In reclaimed , approve feeder It is starting method by

also for big motor changing frequency
DC Converter starting system DC motor for kiln drive Used for conversion of ac
to dc and for motor drive
Convertor starting system Used for weight feeder and For variable speed starting
(VFD) AC variable speed motors control system
Table 1: Different types of motor control system in national cement
2.5 Safety Mechanisms in Motor Starting Method

There is safety mechanism inside the starting method for induction motor starter which provides
protection to the motor as well as the operator of the motor. These mechanisms contain: -
 Fuse
 MCB (main circuit breaker)
 Contactor
 Overload unit (Thermal type)
 Start and stop push buttons
A. Fuse
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 It is a type of low resistance resistor to provide over current protection, of

either the load or source circuit.
 It interrupts excessive current.
B. MCB (main circuit breaker)
 Is an automatic- operated electrical switch designed to protect an electrical
circuit from damage caused by over load or short circuit.
 Its basic function is to immediately a fault condition.
C. Contactor
 An electrical control switch used for switching power circuit, similar to a
relay except with higher current rating.
 Are used to control electrical motor, lighting, heating, capacitor banks,
thermal evaporators and other electrical loads.
D. Over load relay (thermal type)
 Are intended to protect motor, controller and branch-circuit conductors
against excessive heating due to prolonged motor over current up to and
including locked rotor currents.
 When motor overheat due to overload condition, then the main poles latch.
2.6 Motor Winding Section

Winding is the component of motor which receive current from an electrical system. In any
operation of motor due to different reason the winding may be damaged. Motor winding section
is where the motor maintenance is holding.
The main parameter to wind motors is:
 Number of turn: - a turn consists of two conductors which separate each other by the pole
pitch or coil pitch.
 Number of pole (P)
 Number of slot (S)
 Number of phase (m)
 Pole-pitch: - A pole pitch is defined as the peripheral distance between identical points on
two adjacent poles.
 Pole pitch=slot/pole? Coil group.
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 Coil group= phase*pole? coil in series

 Coil series= slot/pole*phase? phase apart (displacement)
 Phase displacement= 2/3*slot/pole.
 Speed = 120*frequency/pole.
 Selecting copper wire and insulator: - select the copper wire diameter according to the
size and quality standard of old data diameter of coil (0.015mm-3mm).
 For insulation insulating paper is used. `
2.7 Types of Winding

A. Single layer winding
When each side of a coil occupies a slot completely without any other coil lying on top of it and
the number of coils equals half the number of slots, the winding is known as single layer
winding. In single layer winding one coil side occupies the total slot area and due to this large
number of conductors is occupied per slot. It is common in small AC machines mostly brushless
dc machine and permanent magnet synchronous machines. Single layer windings have higher
efficiency and quieter operations due to the openings of their narrow slots. The main problem
with single layer winding is crossing of coils in winding over hung part as all coils lying in the
same plane. Those some coils must be bent upward in winding overhang region.
B. Double layer winding
It is said when per slot two coil sides are placed one above the other. North and South Pole are
generated by two coil groups. Used for bigger machine rating typically above 5kw. Due to S-
shape in winding overhang part of coils there are no crossing points of the coils. Slot contains
even number of coil-sides in two layers.
2.8 Substation
The substation of national cement is a station in the power transmission system at which electric
power is transformed to a conveniently used form. The station may consist of transformers,
switches, circuit breakers and other auxiliary equipment. Its main function is to receive energy
transmitted at high voltage from the generating station. For national cement S.C incomer power
are 132kv, 50 Hz and 31.5MW to main substation. The main transformer on substation step
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down the incoming power from 132KV to 6.3 KV distribute to every room which have MV
panel & every electrical room have external transformer to step down 6.3KV to 400V which is
connect to switch gear (control panel) & to sub panel (LV panel). Every panel have voltage
transformer step down from 6.3KV to 100V used to measuring, monitoring and protection.
Figure 30: Main substation
As we know, substation is part of an electrical generation, transmission and distribution system.

Substation transforms voltage from high to low, or vice versa, or perform any of several other
important functions. There are a lots of equipment found in substation. Among these are;
isolator, main circuit breaker, surge arrester, current transformer, voltage transformer, main
transformer etc.
2.8.1 Isolator
 A mechanical switching device, which opens or closes the electrical circuit under no-load
condition for safety, isolation and maintenance. An isolator is capable of opening and closing
a circuit when negligible current is broken or made.
 It is also capable of carrying current under normal circuit condition.
2.8.2 Main circuit breaker (sf6)
 Sulfur-hexafluoride (SF6) is an inert insulating gas, which is becoming increasingly popular

in modern switchgear design both as an insulating as well as an arc-quenching medium.
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Sulfur-hexafluoride is an electronegative gas and has dielectric strength of 2 to 3 times as

compared to air at normal pressure and temperature.
2.8.3 Current transformer (CT)

 Used to display the amount of a current in a line. Its ratio is 300 by one. It means that
300A in reads as 1A at CT.
 Current transformer is used with ammeters, watt meters, power-factor meters, watt-hour
meters, compensators, protective and regulating relays and the trip coil of circuit
breakers. Used to
 Measuring
 Controlling
 Protection
2.8.4 Voltage transformer (VT)

 The pressure of the SF6 gas is generally maintained above atmospheric; so good sealing
of the gas chambers is vitally important. Leaks will cause loss of insulating medium and
clearances are not designed for use in air. This circuit breaker is used at substation used
to display the voltage in line. Its ratio is 132kv/110v.
2.8.5 Power transformer (PT)
 The main transformer in the NCSC step down the incoming line voltage (132kv) to
6.3kv.
 The specification of the main transformer listed below
 CGJC0806-S-E11D-1/18 rev. A
 Primary voltage: 132kv +/- 8x 1.25 %
 Secondary voltage: 6.3kv
 Rated power: 31.5MVA
 Rated current HV/LV: 137.8A/2887A
 Frequency: 50Hz
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2.8.6 Surge arrester

 A surge arrester is a grid component used to protect electric power equipment's from
power spick either from lightning or switching event on the system by creating a low
resistance way to the ground to the existed spick due to lightning or switching event.
2.8.7 Power factor

 The power factor of an AC electric power system is defined as the ratio of the real power
flowing to the load to the apparent power in the circuit, andis a dimensionless number
between 0 and 1. Where the real power is the capacity of the circuit for performing work
in particular time and the apparent power is the product of current and voltage of the
circuit. The reactive power is necessary for the equipment to operate correctly.
 Power factor is also defined as the ratio of active power to apparent power:
𝑃
cos 𝜃 = 𝑆 where P is real power and S is apparent power.
Active power(P): -The actual amount of power being used or dissipated in a circuit.
Reactive Power(Q): - Reactive loads such as inductive and capacitors dissipate zero power, but
they drop voltage and draw current.
Apparent power(S): -the combination of reactive and active power and it is a product of
circuit’s voltage and current, without reference to phase angle.
S=P+ jQ
Capacitor Bank: -is merely a grouping of several capacitors of the same rating.
 It is used for power factor correction.
 It is used for the reduce of reactive power.
 It is also used for store electrical energy
 Power factor correction
In an electric power system, a load with a low power factor draws more current than a load with
a high power factor for the same amount of useful power transferred. The higher current
increases the energy lost in the distribution system, and requires larger wires and other
equipment. Because of cost larger equipment & wasted energy, electrical utilities usually charge
a higher lost to industrial or commercials customers if there is a low power factor or if it is less
than 0.95. Linear loads with low power factor (such as induction motors) can be connected with
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passive network of capacitors or inductors. Non-linear loads such as rectifier, distort can current
drawn from the system. In such case active or passive power factor correction may be used to
counter act the distortion& raises the power factor.
Not only will power factor correction capacitors save your money they will also:
 Reduce heat loss of transformers& distribution equipment.
 Prolong the life of distribution equipment.
 Stabilizes voltage level.
 Increases your systems capacity.
 How to correct power factor?

 Minimizing operation of idling or lightly-loaded motor
 Avoid operation of equipment above its rated voltage
 Replace standard motors as they burn out with energy-efficient motors
 Motor must be operated near its rated capacity to get the highest power factor
 Install capacitors to AC circuit
 Low power factor can cause

 Power loss can occur in distribution system.
 Voltage drop.
 Failure of motors and other inductive equipment.
2.9 Major Challenges & Problems in Internship

1. The working environment is harsh in some working areas, so working inspection tasks may be
hard in those places. Some of those difficult to operate/inspect places include the following
 Kiln area: this place is the hottest place from all the company, the surface temperature of
the kiln shell may reach up to 3000c and above so working around there is difficult.
 The crusher area: this area is mainly known with its high level of dust in the air
surrounding it, and if those dust particles are inhaled it would cause serious health
problem. So off load maintenance is need in there.
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 Compressor stations: those stations are composed of high pressure air compressors.
While in operation they create high amount of sound which can threaten the hearing
system, hence on load inspection process is difficult to accomplish.
2. Lack of heavy duty lifting equipment is another issue. When performing a task involving huge
machineries lifting equipment should be available, for easy and fast process and saving energy.
But in this company lifting is done with bare hands and using chain blocks those places it is
available, those techniques are energy consuming and time taking and should be considered for
replacements.
3. There is no preventive maintenance process available in the company. This means there is
only corrective or shut down maintenance processes have been followed by the company. This
process is not acceptable for huge industries like ours, since shutting down machines for a
specified period of time will cause some profit decrement and minimizes the company’s
production capacity for the downtime of machines.
4. The other challenge we have faced was, the lack of safety equipment provided especially for
internship students as they were not given by the company. The only safety equipment provided
were helmets, other safety equipment like safety shoes, eye glasses and hand gloves were not
provided by the company. This problem made us not to participate in some inspection of motors
due to safety issues.
2.10 Measures and Recommended the Problems & Challenges

Problems exist and their solutions too. During our time in the National Cement SC we have
discovered different problems and issues, some of them were manmade and others already
existed. But still there are solutions for those problems. Many of the problems we faced were
impossible for us to solve hence we give recommendations for the company, so that they will
realize problems solve them by considering the recommendations we gave. Some of the
measures or recommendations for the company to solve the problems existed as listed in the
above sections are discussed as follows:
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 For the environmental problems we recommend the company to provide some safety and
protective equipment for the workers that work in the places like Kiln area, Compressor
stations, and Crusher area. This equipment includes ear plugs, dust masks and safety
glasses.
 For the tool shortage problem, the mechanics should take every necessary tool for
operation. And if possible, they should take the machines to be maintained to the
workshop where every tool is available and comfortable place to work.
 The lifting machine absence problem we have designed an easy one operator controlled
heavy lifting machine have been considered for design in the next section of this
internship report paper. The lifting machine will be able to handle heavy machines and
machine components which couldn’t be handled by manpower.
 Preventive maintenance policy should be main priority for the company. This means
instead of maintaining machineries when they fail, the company should provide
continuous assessment and inspection programs for those machines. Since corrective
maintenance is costlier than preventive maintenance, it should be minimized and
preventive type maintenance should be considered as major priority for the company,
hence preventive maintenance will increase the life time of machineries. Therefore, we
recommend the company to follow this trend instead of the old ones.
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CHAPTER THREE
3. PROFITS WE GAINED FROM THE OVERALL INTERNSHIP EXPERIENCE

3.1 Upgrading Our Theoretical Knowledge:
Theoretical knowledge is any type of knowledge that can be gathered from class also referring
and reading different books and journals. We have been learning in the university for 4 and half
years, hence we have been gathering theoretical knowledge since the beginning of the first year.
In this company we got a lot of practical knowledge as explained above, apart from that we were
also introduced to some new concepts of machines and discovered new machineries that we were
not able to study about them in the university, those new machines include:
 Bag filters
 Fluid couplings
 Material handling systems, such as:
 Screw conveyors
 Bucket elevators
 Belt conveyors
 Air slides
 Apron feeders
 Raw material crushers
 Grinding mills
 Bigger sized motors (both AC and DC motor)
Those machines were present in the company and we got a chance to see them and know about
their working principles. The information and working principles of those machines were
gathered from the company’s Design and Documentation Office. So this internship program has
helped us to upgrade our theoretical knowledge and made us to be familiar with new machineries
from the company.
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3.2 Improving Our Practical Skills:

As the internship program is the main ground for developing practical skills, we were able to
operate and do some inspection of motors and make ourselves familiar with those motors. This
internship program will increase the exposure to machineries which is a big deal to our
department which is connected directly with the real world.
In our time in the company we have working and seen inspection of motors and maintenance
processes of bigger machines and became part of maintenance crew on those maintenance places
and work with the mechanics and engineers. Since practical skill refers to exposing one’s self to
more practical world, we were making this program to be best place to upgrade and develop
undeniable amount of practical knowledge.
Before this internship program, we were unable to perform inspection of motors and
maintenance activities on huge machineries since we never had a chance to work with such kinds
of machines, but this internship program in the National Cement has helped us to have an ability
to work with big machineries as described in the second section (work task accomplished) of this
report.
Basically improving practical skills is made from participating in every of the activities
performed or done. We also developed enormous amount of theoretical knowledge, and
discussed in the following article.
3.3 Improving Our Team Playing Skills:
Improving team playing skills involves in improving one’s achievement, time management,
personal effectiveness, ability of solving problems, ability of decision making and also
communication skills. This internship program was a good place for us to develop those skills in
our minds while working in this company. From the word itself we can understand that, team
playing skill is the skill that you need to organize a certain team and run a certain project on a
specific time, setting the goals that you want to achieve with a better time management skill
taking the responsibility for the project.
In general team playing is an activity involving of leading a specified team for better
achievement and goal which make the company or that specific task to be profitable. In team
playing we performed in the company, we were able to do things in team by division of tasks for
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easy and fast doing of some specified task. Since this skill involves in working with other
peoples, we should expect new ideas and comments to perform specified task, so listening and
accepting new ideas and corrections is a big deal while working in a team. Other criteria are
working peacefully and politely with other team members for a better collaboration.
In our internship period we were able to develop a lot of team playing skill since many work
tasks we involved in were done with other students and company workers. We were able to work
in a team, by developing this skill we were able to:
 Listen to each other with team mates (high level of communication skill had been
achieved).
 Accepting new ideas and criticism.
 Working with other workers with harmony and peacefully.
 Developing high level of problem solving capacity.
All in all, general skills such as; good communication, concentration, fast decision making, self-
confidence and a wellbeing feeling are important for all team members to engage profitable
work. For instance, during our project work we notice that team playing skill is very crucial,
because in our company any work or problems are accomplished with the co-operation of each
other. This situation helps us to develop a team playing skill, since we were one of the members
of the company.
3.4 Improving Our Leadership Skills:

The main aim of having leadership skill is to lead all the workers to get a specific output, since
all the works in the company need a leader with ability to motivate all the workers toward a
common goal. As we already know every section of work needs more experience than theoretical
knowledge, and since in our internship period as we are still students and not yet leaders. We did
not get the opportunity to work in any leadership areas, i.e. we were not able to lead the workers.
But as a saying goes
“If you want to be a leader, then you should learn how to follow”,
While working as internship students we have got a chance to understand the leadership skill
from our supervisors, and know how to lead the workers under one’s command by following
what our supervisors ordered us.
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So in our internship experience we understood the leadership skills and some of them are:
 Ordering workers in a polite manner
 Making decision based on the facts and positive grounds
 Accepting other’s ideas and positive criticism
 Having a self confidence
 Being open minded person
 The ability to begin every work task with a plan
 The ability to handle stress
 Willingness to take responsibilities
 Initiative to work
 The ability to finish work in a given time
 Having a good self-discipline
3.5 Understanding about Work Ethics Issues and Industrial Psychology

Ethics is a branch of philosophy that defines morality and determines the meaning and rational
justification of the right way to live, correct values as well as correct ways of treating others.
Work ethics is being personally accountable and responsible for work that someone does. It
involves attitude, behavior, communication and interaction with others. It is also being
respecting and accepting ideas from others.
Work ethics is a value (personal and cultural) based on hard work and diligence. It is also a
belief in the moral benefit of work and its ability to enhance character. A work ethic may include
being reliable, having initiative, or pursuing new skills.
Personal ethics
These principles of personal ethics are values which are expected to be possessed by all
individual in their life, and contribute a lot for a smooth interaction among individual and
peaceful coexistence of a society. What we gained in the company concerning personal ethics
include:
 Fairness
 Compliant to the law
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 Honesty
 Concern for the well-being of the other
 Refusing to take up unfair advantage
 Doing good
Professional ethics
Professional ethics refers to the standards or a set of moral Principle for regulating behavior of a
certain defined profession. In order to consider that an activity to be a profession, it should be
carried out by one who has advanced education, knowledge, and skills. Thus for developing
health working environment and increase productivity, ethical work conduct is important
medium.
The following are some of the professional ethics what we gained during our internship period.
Punctuality -means keeping the companies work beginning and ending time and to complete a
given task within the given time.
Office discipline- in work place you do not have to disturb the working atmosphere for example
abstains from opening loud voice, loud music, songs and others which may disturb.
Reliability - the worker should be qualified for the task he /she is supposed to perform. He/she
must have appropriate skill and knowledge for the task assigned.
Honesty– regarding this value each worker regardless of its status should abstain from bad
behaviors such as cheating, bias, corruption etc.
Cooperation- each worker should be interacting and cooperate with each other while working.
That is because it is through such system problems could be easily solved.
Industrial psychology
In industries profitability paves the way for growth and keeps a business competitive. However,
profitability is often dependent on multiple factors:
1 A good product
2 Teams that communicate well
3 Employees who are motivated
4 Workers who are well trained and committed to the company goals.
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A success is also tied to a business ‟ ability to identify and resolve workplace issues at both the
individual and organizational level.”
Generally, in our two-month experience we had a chance to highly upgrade our theoretical and
practical knowledge, not only that, we had also changed our behaviors around work areas and we
became ethically well-developed students. We improved our personal and professional ethics
while working with the company’s workers. So it has been a great place to learn the ability to be
fit for any industries and other huge workplaces.
3.6 Entrepreneurship Skills:

During the program we have been developing academic knowledge and practical skills, we
understood how to be in the manufacturing sector. Entrepreneurship deals with identifying a
problem and makes a solution to that problem. We have gained knowledge of entrepreneurship
so as to be self-confident owner and administrator of a company. An entrepreneur is an important
sector even for the countries development because it crates job opportunities to the society. The
idea of creativity is increased when we work hard and try again without fading up through
patience.
To sum up we have gained the following important criteria to be successful entrepreneur.
 To be flexible in own demand
 Listen others idea and believe on compromise
 Avoid fear of failure
 Obey laws of the entrepreneur
 Be acceptable compromise
 Have clear goal setting
 Effective use of resources
 Long term involvement
3.7 Improving Our Interpersonal Communication Skills:

Through our internship period we made a lot of friends among the workers of the company.
Hence we were able to communicate with each of the workers especially from our department,
and our ability to understand the workers has been increased. Our interpersonal communication
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ability has been grown from time to time since the beginning of the internship program, since we
were afraid to approach to the workers and ask them about the machines and some information
about the company.
Interpersonal communication helps workers to be able to work together and support each other
through many things in life; it also includes listening and accepting others thought and being
open minded. In the two-month period we have got a lot of knowledge apart from the practical
skill, for example we know how to communicate and contact with our supervisor and other
company’s officials.
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CHAPTER FOUR
4. CONCLUSION AND RECOMMENDATION

4.1 Conclusion
We have joined National Cement Share Company to take our internship program, in particular to
develop and gather more theoretical and practical skills from the elder workers and engineers of
the company. The internship period had been the most important time and the company as an
important place for developing those basic skills and knowledge apart from what we had been
learning in the university.
The internship semester makes the new curriculum. So good to give real practical skills and
make the students familiar to the outside world. Generally, we get the following benefits.
 We know the company work flow
 Upgrade our theoretical knowledge
 We progress leader ship skill
 We identify work standards
 We recognize time management
Generally, we have gained a good practical knowledge the filled of industrial process control,
electrical maintenance and electrical power distribution and we have become more familiar with
different kinds of electrical equipment’s and tools that are used in the working process. And
somehow we have seen the working environment, so that we will prepare ourselves for future
mentally and emotionally.
On the other hand, it is the first time in our life to involve formally and deeply in the practical
areas and for a long time we were just learning something theoretically and it is somehow
difficult to visualize and time consuming to understand. But this internship program has helped
us well to understand those concepts more easily than the formal way of learning.
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4.2 Recommendation
4.2.1 Recommendation to the Company

While working in NCSC we have been facing different problem. For those problems we have
given recommendations bellow:
 The internship program should start on the due day.
 Safety equipment should be provided fully
 It is batter if the company give mini project for the intern students
 As the train engineers the intern students also should get attention.
 The company should give big attention for the environment
 The company should work on improving the skills of technicians not only the engineers
4.2.2 Recommendation to the University

 Before the internship the student must take essential courses such as PLC.
 The university should provide different soft wear courses
 The university should create a means of communication between the intern and the
adviser.
 After the students gone out for the internship the communication between the university
and the intern should not be terminated.
 Provide online courses for the inter
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REFERENCES
1. [1] automatic coil winding machine by sundar ganesh ccs*.
2. Austin Hughes “Electrical Motor and Drives: fundamentals”, type and application
3. V,B. Bhandari, “ Design of machine Elements” Motor”
4. From NCSC technicians
5. www.plc tutor.com
6. www.siemens.com
7. Basic electrical machine NCSC company manual
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Haramaya University Haramaya Institute of Technolgy School of Electrical and Computer Engineering

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HARAMAYA UNIVERSITY

HARAMAYA INSTITUTE OF TECHNOLGY

ASHENAFI TURI………………………………………………. R/0323/09

DURATION OF INTERNSHIP: JUNE 15/2021– AUGUST 06/2021

Name of students: Signature: Date:

Approval of advisors Signature: Date:

Mr. Gechanu.A -------------------- ----------------------

Approval of company supervisor Signature: Date:

Mr. Abay Firew -------------------- ----------------------

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Key words: - PLC

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2.8.1 Isolator ....................................................................................................................................... 38

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Table 1: Different types of motor control system in national cement………………………………….35

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1. BACKGROUND OF THE NATIONAL CEMENT SHARE COMPANY

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Figure 1: National Cement Entry

 Focus - pursue focused strategies that create competitive advantages.

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 Commitment - provide customers with better value and services

 Performance – deliver the highest quality products to our customers.

 Sustainability – build enduring partnerships with customers and suppliers.

 Integrity – ensure all business dealings are ethical and transparent.

1.2 Main Products of the Cement Company

1.2.1 Ordinary Portland cement (OPC)

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Figure 2: Products of National Cement, OPC

1.2.2 Portland Pozzolana Cement (PPC)

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Figure 3: Products of National Cement, PPC

1.3 Main Customers of the Company

 Growing domestic construction industry

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1.4 Overall Organization and Work Flow

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1.5 Work Flow of the Company’s Production

Figure 4: Quarry, raw material blasting area

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Figure 5: Raw material crusher area

2. Prehomogenization the next process. In cement production, it is often necessary to

Figure 6: Pre-homogenization and blending area

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Figure 7: Proportion silos

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Figure 8: Vertical Roller Mill

Figure 9: Bag house and Homogenization silo

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Figure 10: Pre heater

Figure 11: Rotary kiln

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Figure 12: Great cooler

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Figure 12: Clinker silo and Cement grinding mill

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Figure 13: Cement silos

Figure 14: Rotary packer

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