.

DIRE DAWA UNIVERSITY

INSTITUTE OF TECHNOLOGY
SCHOOL OF ELECTRICAL AND COMPUTER
ENGINEERING
INDUSTRIAL CONTROL CHAIR
Internship report and project
Host Company: East Africa Bottling Sc
PREPARED BY:
NO. GROUP MEMBERS ID NO

1. ELIAS MAMO 1002497

2. HABTAMU ABERA 1002164
3. MEKDES ABYU 1002245
4 JAFER JIRU 1103693

ADVISOR NAME: Mr. V.Raja Gopal

Submission Date:
Dire Dawa, ETHIOPIA
 DECELERATION
We are a 5th-year Electrical Engineering student at the Dire Dawa Institute of Technology. And
we have undertaken our internship experience in East Africa Bottling Share Company for three
months under the guidance of our supervisor Mr. Dereje Shawel and our advisor Mr. V.Raja
Gopal. Finally, we are intended to tell you that this document is a good indicator of how much
effort we made to go steps forward in the practical world by integrating it with theoretical
knowledge.

We clarify that our work is original and compiled according to the internship report writing
guideline given by the Institute.

Name of Student Date Signature

1. ------------------------ -------------- ------------

2. ------------------------ ------------- ------------

3. ------------------------ -------------- ------------

Approval of advisors Date: Signature:

Mr. V.Raja Gopal ------------------ --------------

Approval of company supervisor ------------------ ---------------

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Acknowledgment
Firstly, we would like to offer our deepest gratitude to God; second, we would like to thank Dire
Dawa University Institute of Technology (DDUIT) for giving us this opportunity. And we would
like to thank our advisor Mr. V.Raja Gopal for his critical comments and valuable support. And
we would like to thank our supervisor Mr. Dereje Shawol who was guiding us in our all
activities. We would like to express our deepest thanks to all of the EABSC staff members.
Especially, Mr. Tekeba and Hiwet wastewater treatment operators, Mr. Yard electrical
automation specialist, Mr. Mifta electrician for their advice, suggestions, Mr. Alem boiler
operator and encouragement sensationally who gave their immense support, dedicated their time
towards it and made us understand how to perform our project. And for last but not least, I want
to give my gratitude to EABSC DD plant managers and all operators.

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Executive Summary
This document consists of the internship report and project that we have performed in the
internship program from March 19 to June 20/2022. It includes the background, mission, vision,
main products, and main customer of the East Africa Bottling Share Company and overall
organizational structure of my internship hosting company. The report covers our overall
internship experience, benefits, the challenges that we have been facing, and the measures we
have taken to overcome those challenges and recommendations.

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 Table Contents

Contents
DECELERATION....................................................................................................................................i
Acknowledgment.....................................................................................................................................ii
Executive Summary................................................................................................................................iii
Table Contents........................................................................................................................................iv
PART ONE CHAPTER ONE
INTRODUCTION...................................................................................................................................1
1.1, BACK KGROUND OF THE COMPANY.......................................................................................1
1.2, Vision, Value and Mission of the company......................................................................................2
1.2.1. Vision of the company...................................................................................................................2
1.2.2. Values of the company..................................................................................................................2
1.2.3. Mission of the company.................................................................................................................2
1.3. Main services of the company..........................................................................................................2
1.4. The main customers of the company................................................................................................3
1.5, Organization structure of the company.............................................................................................3
1.6. Workflow of the company................................................................................................................4
CHAPTER TWO OVERALL INTERNSHIP EXPERIENCE...............................5
2.1. How we get in the company.............................................................................................................5
2.2. The Activity of the company we have been working on...................................................................5
2.3. The Section and Workflow in the company......................................................................................5
2.3.1, Raw water Treatment.....................................................................................................................6
2.3.2, Water Softener.............................................................................................................................10
2.3.3. Wastewater Treatment.................................................................................................................11
Boiler Room..........................................................................................................................................15
Unpacker Machine.................................................................................................................................23
BOTTLE WASHER MACHINE...........................................................................................................23
BLENDER/MIXER...............................................................................................................................28
FILLER MACHINE..............................................................................................................................32

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Crate Conveyor......................................................................................................................................37
Date Coder.............................................................................................................................................37
Packer Machine.....................................................................................................................................37
2.4. THE WORK TASK THAT WE HAVE BEEN EXECUTING.......................................................38
2.5. THE PROCEDURES USED WHILE PERFORMING THE WORK TASK..................................38
2.6. HOW GOOD WE HAVE BE EN IN PERFORMING OUR WORK TASK..................................39
2.7. THE CHALLENGES WE HAVE BEEN FACED DURING THE INTERNSHIP........................39
2.8. MEASURE WE HAVE TAKEN TO OVERCOME THE CHALLENGES...................................40
2.9. Design and construction in terms of safety and economy...............................................................40
CHAPTER THREE OVERALL BENEFIT OF THE INTERNSHIP.................................41
3.1. IN TERMS OF IMPROVING PRACTICAL SKILLS...................................................................41
3.2. IN TERMS OF UPGRADING OUR THEORETICAL KNOWLEDGE........................................41
3.3. IN TERMS OF IMPROVING OUR INTERPERSONAL COMMUNICATION SKILLS.............42
3.4. IN TERMS OF IMPROVING OUR TEAM PLAYING S KILLS.................................................42
3.5. IN TERMS OF IMPROVING OUR LEADERSHIP SKILLS........................................................42
3.7. IN TERMS OF IMPROVING ENTREPRENEURSHIP SKILLS..................................................43
PART TWO...........................................................................................................................................44
PROJECT..............................................................................................................................................44
TITLE: FEED WATER HEATING SYSTEM WITH TEMPERATURE AND LEVEL CONTROL
FOR BOILER........................................................................................................................................44
ABSTRACT..........................................................................................................................................44
CHAPTER ONE INTRODUCTION...................................................45
1.1. BACKGROUND OF THE PROJECT............................................................................................45
1.2. Problem Statement..........................................................................................................................45
1.3. Objectives 1.3.1. General objectives...............................................................................................45
1.3.2. Specific objective........................................................................................................................45
1.4. Significance of the project..............................................................................................................46
CHAPTER TWO LITERATURE REVIEW........................................47
CHAPTER THREE METHODOLOGY...................................................48
3.1, BLOCK DIAGRAM.......................................................................................................................48
3.2, THE COMPONENTS USED IN DESIGNING THIS PROJECT..................................................49
3.3, FLOW CHART............................................................................................................................56

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3.3.1, Algorithm of the flow chart.........................................................................................................57
3.4, SYSTEM DESIGN Proteus Design Suite.......................................................................................58
The Proteus Design Suite is a proprietary software tool suite used primarily for electronic design
automation. Mainly electronic design engineers and technicians to create schematics and electronic
prints for manufacturing printed circuit boards use the software...........................................................58
3.4.1 Working principle of circuit diagram............................................................................................58
CHAPTER FOUR RESULT AND DISCUSSION............................................59
4.1 SIMULATION RESULT................................................................................................................59
4.2 DISCUSSION..................................................................................................................................61
References.............................................................................................................................................62
Appendix...............................................................................................................................................63

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 PART ONE
CHAPTER ONE
INTRODUCTION

1.1, BACK KGROUND OF THE COMPANY

The product that has given the world its best-known taste was born in Atlanta, Georgia, on May
8, 1886. Dr. John Stith Pemberton, a local pharmacist, produced the syrup for Coca-Cola, and
carried a jug of the new product down the street to Jacobs' Pharmacy, where it was sampled,
pronounced "excellent" and placed on sale for five cents a glass as a soda fountain drink.
Carbonated water was teamed with the new syrup to produce a drink that was at once "Delicious
and Refreshing," a theme that continues to echo today wherever Coca-Cola is enjoyed.

Coca-Cola products were first sold in South Africa in the early 1930s and, in 1938, the company
opened its first office in the country. By 1981 the company's products accounted for 90% of the
soft-drink market and by 1983 company sales were reportedly more than $260 million, with
assets valued at over $60 million. Since then the company has reduced its investment in South
Africa, selling its Letaba Citrus Processors subsidiary in early 1985 and reducing its stake in
Amalgamated Beverage Industries from 60% to 40% in January 1986.

Coca-Cola was first bottled in Ethiopia's capital Addis Ababa in 1959 by the Ethiopian Bottling
Share Company, which later opened a second branch in Dire Dawa in 1965. The two plants were
nationalized in 1975 and ran as public companies until 1996 when they were bought by private
investors. Just prior to that, in 1995, the Coco-Cola South African Beverage Company (Coca-
Cola SABCO) bought shares in the business and 1999 signed a joint venture agreement with the
plants. In 2001, Coca-Cola SABCO increased its shares to 61 percent and the company changed
its name to the East African Bottling Share Company. EABSC continues to run the two plants in
Addis Ababa and Dire Dawa.

EABCS focuses on bottling and distributing coca cola products. The company continues to the
three branches in Addis Abeba, Dire Dawa, and Bahir dar. In 2011 Coca Cola sabco again start
expanding the business at Dire Dawa by installing a new bottling line to increase the production
volume by 100% and started production end of February 2012. In 2014, the old lines (Line 1 and

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Line2) are decommissioned. Line 1 is upgraded with a new washer and KHS filler and blender
from old-line 1. An additional new line (Line 5) is installed and commissioned in August 2015.

1.2, Vision, Value and Mission of the company

1.2.1. Vision of the company

To be the best beverage drink in the world and Africa’s most valuable independent of <food and
beverage company.

1.2.2. Values of the company

We have a passion for the coca cola business and the brand.

 We think and act as owners all the time.

 We have a passion for our business brands, customers, people, and communities in which
we operate.
 Accountability is clear and personal
 We work and win in a team across the business.
 We are humble but confident in all we do.
 Safety, quality, the environment, and our community are integral to our working lives.

1.2.3. Mission of the company

We strive to satisfy our key shareholders every day.
 Our customers are the center of all our actions.
 Our customer ‘LOVE’ for our brand grows as they purchase ice-cold quality production
for every occasion at ‘arm’s length of desire.
 Our customer shareholder is well rewarded over the long term.

1.3. Main services of the company

The capability of the company in providing its services increases over time by introducing new
additional brands. The EABSC DD provides the following products:

 Coca-Cola

 Fanta (orange)

 Sprite

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1.4. The main customers of the company
EABSC distributed its product to all over east Ethiopia regions and cities. It includes Dire Dawa
city to Somali, Harar, Oromia, and Afar regions. The customer of the company extends from
large trade organizations to small distributing units then finally, to the consumers. For instance:
Small beverage distributor units and shops, Hotels and Supermarkets.

1.5, Organization structure of the company

The company has a structural working system that promotes the working environment through
the corporation. The structural organization of the company is can be schematically represented
as follow.

Figure 1: Organizational structure

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1.6. Workflow of the company
The company first distributes its products to its temporary storage units called OCCD (Official
Coca-Cola Distributer).

Figure 2: Workflow of the company

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 CHAPTER TWO
OVERALL INTERNSHIP EXPERIENCE

2.1. How we get in the company

We select this company because it is a worldwide industry where we can see every theoretical
part that we learned from school. So that being in this company upgrades our theoretical
knowledge and makes us see every theoretical part we learned before practical skill. This is why
we decided to select this company. The way we get into his company is by interview. Dire Dawa
university institute of technology linkage notices that students from Dire Dawa University can
apply to get into this company by certain criteria. Those criteria were GPA grade of the student
should be 3.00 and above. Then we are registered in the industry leakage office and our names
are sent to the East African bottling share Company (Coca-Cola) the company noticed that
selected candidates can come for an interview then we interviewed and finally, the company
selected us to start this internship program.

2.2. The Activity of the company we have been working on.

We have been working on the following sections of the company. Such as in water treatment,
wastewater treatment and discharging wastes, boiler, chiller (refrigeration) machines, bottle
washer, EBI and FBI, blender, maintaining filler, cleaning blower, packer, unpacker, In quality
checking and we also working on inspection of the bottle.

2.3. The Section and Workflow in the company

The Coca-Cola factory in Dire Dawa is comprised of several plants which are interacted and
integrated to produce the final product, soft drink. These plants are mainly divided into three
sections, Utilities, Water treatment plants and plants in the production area.

Table 1: Sections and plants in the factory

Water treatment plants Utilities Plants in the Production

area
Raw water treatment Boiler Washer
Water softening Chiller Blinder
Wastewater treatment Compressor Filler

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 Figure 3: Overall processes of the factory

2.3.1, Raw water Treatment

Since finding clean water in a huge amount is rare, almost all industries run the water treatment
process as among of the most important processes for the production of any desired product.
Water treatment is the process of removing any contaminants from the water and converting it to
the suitable and useful for the desired purposes; such as for drinking, cleaning, steam energy
generation, and others. The Coca-Cola factory (EABSC DD) uses groundwater as a water source
for its whole processes and utilizations that require water.

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Components of the Raw water treatment plant
The main components of a water treatment plant

 Borehole water source

 Raw water storage tank
 Reaction tank
 Lime mixing tank
 Sand filter
 Buffer tank
 Activated carbon filter
 Polishing
 Reverse osmosis
 UV light
 Storage tank
 Reserve tank

Figure 4: Raw water treatment

1) Pumping from Borehole

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The raw water that is confined underground (beneath 200m) is sucked up by pumps and sent to
the concrete reservoir. The water that sends to both the raw water treatment plant and raw water
softener plant is from this reservoir.

2) Reaction tank
The raw water in the reservoir is sent to the reaction tank which is the first tank in the raw water
treatment plant with the capacity of 100,000m3. In this reactor, three chemicals are added
proportionally for different purposes. Those are

a. Chlorine (Cl): By its nature chlorine is a highly poisonous chemical for living things. It is
used that eliminate any living organisms (microorganisms) such as bacteria and other microbes.
b. Ferrous sulfate (FeSO2): Ferrous sulfate is used as a coagulation agent in water treatment.
Coagulation is the process by which particles become destabilized and begin to clump together.
To do this, FeSO2 is dissolved in the water and then precipitates. While it precipitates, it adheres
to other suspended solids and forms flocs. These tend to settle down since the specific gravity
becomes greater than that of the water.

c. Milk of Lime /Ca(OH)2: Lime (CaO) is fed to the lime mixing tank and it becomes mixed
with water with the help of an agitator to form Ca(OH) 2. This milk of lime is used to reduce the
hardness of the water by removing Ca and Mg ions. The Ca and Mg removal mechanism is as
the following. Ca and Mg are found in the water in the form of Ca(HCO 3)2 and Mg(HCO3)
respectively.

3) Sand filter
In the sand filter tank, the suspended matter and floating particles are removed. This tank
involves a fine bed of sand. It removes these particles by an absorption mechanism. Those tanks
are two in number and which work in the same way though, to enhance the treating performance.
This filter needs to be cleaned by an up-flow of water (called backwash). A simple sand filter
has varying particle sizes and when it is Backwashed, the finest particles are on top and these
particles are responsible for filtration.

4) Activated carbon (A.C)

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Before entering into the A.C filter, the chlorine-rich water left in the sand filter is stored in a tank
called a buffer tank. In an A.C filter, any organic matters or compounds that cause bad odor or
taste are removed. The treated water from semi treated tank at the bottom is transferred into the
carbon filter in which chlorine is trapped (adsorbed) by carbon. The activated carbon is removing
traces of impurities by the process of adsorption and reduction. This process was also carried out
in two tanks for better performance.

5) Polishing
Polishing is a process whereby very fine suspended particles are removed from the water. This is
done by passing the water through a polishing unit containing special unit filter membranes.

6) UV light
UV light is electromagnetic radiation with a higher frequency (energy). This energy has the
potential to penetrate the cell wall of any micro-organism. Therefore, UV light is used to remove
any micro-organism that can contaminate the water and the effectiveness of the RO filter.

7) Reverse Osmosis (RO) filter

Reverse osmosis means the transportation or the flow of water from the high concentration of
solute to low concentration by the application of pressure in a reverse direction of osmotic
pressure. This process removes any chlorine and salt contents in the water. In RO, an ultrafilter
membrane is used as a filter medium. The water that does not fulfill the purification quality after
RO is sent to the semi-treated tank. This semi treated water serves as a shower, hand washing,
and for other purposes that can workers use directly. And fully treated water is sent to syrup
proofing, filler, boiler, and washer after it is stored in the treated water reservoir and treated with
UV-2.

The RO plant consists of the following main components, these are

 Cartridge filters to remove particulates.

 High pressures pump to develop the required pressure.
 A set of membranes housed in pressure vessels
 Piping and valves

8) Treated water tank

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 The water after passing through all these processes is needed to store in the reserve tank. The main
function of the treated water tank is to act as a reserve container. The treated water is used for.

 For syrup production.

 Used in the filler area.

 For line lubrication.

 For boiler and other essential areas.

The treated water tank acts as a distribution medium for all these lines. At the water outlet of the
storage tank, there is another UV light treatment. This is why if the microbe is developed in the
storage tank it is a means to protect the biological hazard.

Figure 5: water treatment overall process diagram

2.3.2, Water Softener

The water softening process is a process of removing components in the water that are the causes
of the hardening of water. From such components, Magnesium and Calcium are commons. There
are several methods to make water soft. From those methods, our hosting company uses an Ion
exchanger. This ion exchanger removes calcium and magnesium by the means of absorption

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using an appropriate resin, which is Zeolite. This zeolite is anionic so, it traps Ca and Mg
(cations). When the zeolite is full, it is allowed to be washed by NaOH to regenerate it.

Processes
The raw water is pumped from the ground by the lift pump and pour it into the tank after this the
operator adds 100 kg of sodium chloride to the tank for the purpose break down the hard bond of
calcium and magnesium within a 3-hour interval finally storing this soft water in a tank.

The softened water used in: washer, cooling tower and boiler

2.3.3. Wastewater Treatment

Wastewater is the water discharged from process effluents after being used as a process fluid and
carries pollutants during processes. The pollutants may vary according to the processes the water
is used. Wastewater treatment is the process of taking wastewater and making it suitable for
discharge back into the environment without environmental impact.

Source and characteristics of wastewater

The wastewater in our plant is mainly generated from the production room and water treatment
plant. The main waste generated in the production room is the Coca-Cola products discharged
from the process, the caustic solution from the washer, and the CIP processes. In addition
detergents and lubricants from different machine parts are also the sources of pollutants in the
production room. Besides this, in water treatment, there is also a high amount of wastewater
generated from the lime reactor tank from the sand filter, from the carbon filter, and all other
parts of the plant. In general, the waste generated in our plant is mainly basic having a PH value
between 6 and 13.

The Overall process of the wastewater plant

The waste treatment plant is working under the biological treatment principle. Biological
treatment is the decomposition of organic waste with the activity of microorganisms.
Microorganisms have their life cycle of living and dying. The way to treat the waste is that
microorganisms feed the waste to develop and replicate their mass. The waste treatment plant in
our case has the following components;

 Inlet pump pit

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  Grit channel with coarse screen
 Oil trap
 Pump station with pre neutralization
 Dosing station for sulphuric acid, ferric chloride and nutrients, and polymer.
 Aerated equalization basin
 Dual SBR system
 Aerated sludge storage tank and
 Belts filter press for sludge dewatering.

Description of the plant

Inlet pump pit
The waste generated from different sources is collected in the inlet pump pit. This is the area
nearer to the waste sources and is acts as a reservoir for wastewater. Two submersible pumps are
installed in the inlet pump pit for pumping the collected waste to the treatment area.
Grit channel

The first step in wastewater treatment is known as the preliminary treatment and starts with
screening in the grit channel. The grit channel is a concrete-walled ground tank where
pretreatment is started. Two coarse screens are used to keep coarse particles and coarse foreign
particles like plastics, broken glasses, and crowns from passing to the next step. This helps to
prevent the trance of ungradable and dissolvable particles and also prevents pipes and valves
from plugging abrasion and cutting. Foreign matter holds on there is cleaned manually whenever
necessary.

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 Figure 6: Grit channel

Oil skimmer

The next area of pretreatment after the grit channel is the oil skimming section. The wastewater
may contain some oily components from the lubricants of machine parts. The oil is non
decomposable by bacterial activity and will also limit bacterial activity. The other disadvantage
of the presence of oil in the wastewater is that it will collect solid in the internal part of piping
and valves of the treatment plant. That is why oil needed to be skimmed. The principle is the
density of the oil is lower than the density of water the leads the oil to float over water. The belt
chain rotates when the level sensor initiates and collects the oil and discharges it in the oil
bucket.

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 Figure 7: oil skimmer

Pre neutralization (equalization) tank

Pre-neutralization is the area where primary treatment starts. Neutralization is the process of
treating acid with a base or vice versa to reduce the harmful effects of acidic and alkaline
effluents. In our case neutralization is the addition of H2SO4 solution to reduce the alkalinity of
the waste caustic effluents from washer and lime effluents from water treatment. The waste is
mainly basic and has a PH of up 13. This highly alkaline solution is not suitable for microbial
activity; the microbes will die or will not work efficiently, therefore our biological process will
not work. . The equalization tank is a dual-purpose tank which is the final neutralizing tank, and
the startup of biological decomposition organic waste.

SBR1

The SBR1 tank is an aerated biological reactor that converts organic carbon in the waste into
sludge through microbial activity in the presence of air. The bacterium is first stabilized with the
nutrient. After the bacterium is stabilized by feeding the nutrient biomass of bacteria will be
created. The biomass is capable of feeding and converting the decomposable substrate into the
effluent. The submersible aerator in the reactor helps for efficient mixing of substrate and
biomass.

SBR2

SBR2 tank is also an aerated biological reactor working the same principle as the SBR1 system.
The difference is that the unconverted substrate in SB1 is converted in SBR2. This is the final
reaction tank where effluent at the top is discharged to the environment and the bottom product is
pumped to the aerated sludge tank for further stabilization and stage completion for final
discharge.
Sludge dewatering

Sludge dewatering is the removal of water is the reduction of liquid volume of water in the
sludge. Reduction of water contents of sludge is helped for reduction of the volume of sludge
needed to be discharged and also for easy handling of sludge during transportation of sludge.

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Sludge is dewatered in the sludge dewatering machine which consists of a movable belt for
pressing sludge to reduce the water and solidify the sludge. The machine operates with the
application of a polymer that is used for the flocculation of sludge. The polymer is hydrophilic
and helps to expel water from the sludge and also to flocculate the sludge

Figure 8: Process of wastewater treatment

Boiler Room
The boiler is one type of heat exchanger, which uses water to produce steam energy. In any
utility room of plants, the boiler is found to be the most essential and common, which can be
considered as the power heart of the whole plants in the factory. The EABSC (Dire Dawa) uses a
fire tube boiler. Fire tube boilers are those boilers that use high-temperature flame generated in
the tube side to heat the water at the shell side of the boiler. Fire-tube boilers consist of a series
of straight tubes that are housed inside a water-filled outer shell. The tubes are arranged so that
hot combustion gases flow through the tubes. As the hot gases flow through the tubes, they heat
the water surrounding the tubes. The water is confined by the outer shell of the boiler.

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 Figure 9: boiler

Figure 10: fire tube boiler

Component of the boiler

The boiler system constitutes many components to acquire the required pressure and temperature
of steam from the starting feed water, some of the components of the boiler are,

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  Burner
 Corrugated furnace
 The shell side steel part
 The fire tubes
 Front and back smoke box
 Air filters
 Oil filters
 Blow off cock
 Feed check valve
 Condensate infeed line
 Screw pump and centrifugal pump
 Mobrey water level controller
 Level sensor
 Pressure sensor
 Temperature sensor
 Safety valves
 Electrical control panel

Burner

The burner is heart of the boiler, which provides the fuel or heat input to the boiler. The high
thermal efficiency and the trouble free operation of the boiler will mainly depend on its design,
its compatibility with boiler, ability to burn the desired fuels with high efficiency and reliability
of the components,

 The burner motor

 Oil hose connection
 The servo motor
 Solenoid valve
 Photo sensors
 Oil filter
 Air regulator/Dumper
 Oil preheater

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  Electric and fuel connections

Figure 11: Burner

Apart from the machine components, the boiler needs the inputs to attain the required output.
The boiler uses the following as an input:

 Heavy furnace oil(HFO): the burning component

 Air: oxygen supply
 Water from hot well: water to be boiled
 Chemicals: for the boiler’s safety and long life

Working principle of smoke tube boiler

 Water from the hot well tank flows down to the boiler through gravity and is pumped by
feed pumps working continuously. The feed water in the boiler is accumulated in the
shell side of the fire tube Thermax boiler. Heavy fuel oil stored in the HFO reservoir tank
is pumped through the gear pump to the fuel preheating station where fuel oil is heated in
the preheater to reduce the viscosity of the fuel. When the viscosity of the fuel is higher
the flow of resistance will be higher. Therefore to reduce the flow resistance the oil is

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 needed to be heated. After the heavy fuel is heated the oil is then going to the oil filter
where any foreign material is retained there. The filtered oil is then going to the oil
burner where fuel combustion starts and there is a heater in burner that is used to heat the
oil again. The preheated oil is then combusted with the atmospheric air coming with
nozzles fire ignites by two high voltage electrodes sparking. The servo motors adjust or
balance the amount of oil and air by sensing the pressure in the boiler through a pressure
transmitter. When the ignited fire flames through the corrugated furnace the smoke is
produced and this smoke or hot gas is passed through the three pass fire tubes to heat
water inside the boiler is filled in a shell side, the water is boils at high temperature,
finally produce steam and the smoke is removed through the chimney.
 There is also sensor in the boiler those are temperature sensor, pressure sensor and
mobrey water level controller. There are three switches in the mobrey first top switch is
used to put off the feed water pump, the second middle switch is used to put on the feed
water pump, and the third switch at the bottom is used for providing extra low-level
alarm and burner trip.

Figure 12: flow sheet of the boiler

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Steam generated in the boiler is used in

 For Bottle washer: empty bottles used by the customers are washed in a washer machine
that uses heated caustic. Steam is to heat this caustic.
 For CIP in water treatment plant: in this plant, there may be a leakage of chlorine from
the activated carbon tank, during this phenomenon, steam regeneration CIP is found to be
effective, which uses steam to regenerate(activate) the carbon.
 For CIP in the production area: in this area, CIP is carried out by hot caustic once in
72 hours. Steam is used to boil this caustic.
 For Sugar dissolving in simple syrup preparation: simple syrup is prepared by
dissolving filtered sugar at moderate temperature.

The water that was later converted to steam in the boiler has its physical, chemical, and
biological characteristics. The quantities of these characteristics should be in their standard range
so that prevents the boiler from different damages. To do this, the entering water should be
treated well using several chemicals; such chemicals are phosphate-based antiscalant
(HYDREX 1255) and sulfite-based anti-corrosion (HYDREX 1308 oxygen scavenger). The
boiler also has frequent blowdowns to get rid of solids accumulated in the water.

Chilling Unit
A chilling unit is a unit that generates chilled water, which is used as refrigeration in several
parts of the factory. Chillers use refrigerant gas to move the unwanted heat between the
evaporator and the condenser. The chilled water is generated in the evaporator and sent to the
required section. The EABSC uses a water-cooled centrifugal chiller type.
Working principle of chiller
The centrifugal chiller uses the vapor compression cycle to chill water. It throws off the heat
collected from the chilled water plus the heat from the compressor to a water loop. The water
loop is cooled by a cooling tower. There are four basic components of the refrigeration cycle.
Compressor
A centrifugal compressor converts rotational kinetic energy to the dynamic energy of the fluid
flow. Refrigerant enters the pump impeller and is accelerated, flowing radially outward, then

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exits. The process raises the pressure of the refrigerant by converting kinetic energy into pressure
and heat.
Cooling tower
The water from the softener enters the cooling tower and get cooled by a forced convection
system that uses a high-speed mechanical fan.
Condenser
The condenser in our chilling unit is a shell and tube-like condenser used to condense the
vaporized or heated refrigerant gas. The water used in the condenser to condense gas is returned
to the cooling tower and get cooled by a forced convection system that uses a high-speed
mechanical fan and circulates.
Evaporator
The cooler is used to freeze the cooling water to the required temperature of around 4°c-10 oc.
Refrigerant gas after condensed in the condenser and passes through the expansion valve drops
its temperature and pressure, the refrigerant gas then passes through the shell tube side of the
cooler and freezes the water in the shell side.

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 Figure 13: chiller process diagram

The compressor
A compressor is a mechanical device that increases the pressure of a gas by reducing its volume.
An air compressor is a specific type of gas compressor and compressors are similar to pumps
both increase the pressure as fluid and both can transport the fluid through a pipe.

The working principle and process

The working component of the compressor is mainly composed of several different mechanical
systems. Those components are arranged and installed as the following
1) Air separator
The air that is sucked from an environment consists a number of gas components. An Air
separator is a device that removes entrained air (micro bubble) that is moving with the flow of
the fluid.

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2) Air filter
The air that is compressed at the required pressure is allowed to be filtered. An air filter is a
device that is composed of fibrous or porous material which removes solid particles such as dust,
mold, and bacteria from the air. The Filter contains air adsorbents that can remove odors and
gaseous pollutants such as volatile organic compounds.
3) Air dryer
As the air in the compressor cools, water vapor condenses into the tanks, pipes, hoses, and tools
that are connected to it. This moisture affects the equipment that is mentioned. The air dryer is
applicable for moisture removal pump purposes.
The compressed and filtered air is used in:
 Packer and unpacker
 Washer
 Pneumatic valves
 Blender
PRODUCTION SECTION

Unpacker Machine
Unpacker machine is where empty glass bottles came out from the crate and placed on the
conveyor belt to transport to bottle washer. The unpacker machine uses pneumatic system to
suck the glass bottles and move them to the conveyor.

BOTTLE WASHER MACHINE

The beverage containers (bottles) returned from the customer, are highly contaminated and dirty.
To reuse them, the factory must clean and wash them, and also the construction of the washing
system has to be highly mechanized and effective to keep the demand and supply rate in balance
and to fulfill the sanitation standard. The EABSC DD uses a washing machine called Sidel-
OCEANO – SLZC.0061.
Working Principle
The washing machine uses the following as input:
 A Large amount of water from the softener
 Caustic soda (NaOH), 2%

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  Steam from the boiler
Utilities required
 Air pressure: 6 bar
 Water pressure: 1.55-1.9 bar
 Steam pressure: 4 bar
The water is mixed with caustic and the steam heats. The heated caustic and water, wash any
contaminants from the bottle internally and externally. Internally: by spraying the warm caustic
inside the bottle with high pressure (4bar) by spraying jets and externally: by showering using
showering units.
The washing process has the following steps:
1) Bottle feeding
Before feeding empty bottles to the washer, the dirty empty bottles are unpacked from their crate
using an unpacker machine. The crate goes to the crate washer and the empty bottles go to the
bottle washer. In the middle of traveling to the washer, the empty bottles get rinsed with water
using some spray jets. This is to remove large materials found on the external surface of the
bottle, which can help the washing process in the washing machine. Also, the bottles are
inspected whether the correct bottle type is passing or not during filling a specific beverage. The
bottles are transferred from the deck to the loading beam using the clamps, which lift them by the
bottom and take them from the deck to the guide for a short distance, then a pushing cam inserts
them into the pockets. This double movement ensures continuous motion without jerking the
bottles.

Figure 14: Bottle feeding

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2) Pre-wash
In the prewash area, the bottles pass through spraying zones: each area includes internal low-
pressure sprays and an external sprinkler section. In this area, the bottle temperature is gradually
increased using the residual heat of the water coming from the rinse area. At this stage, coarse
contaminants such as cigarettes, metal segments, cuts of plastics, and others are removed.
Everything that comes out of the bottles is collected and discharged from the machine along a
channel.
3) Soaking
The pre-rinsed bottles enter the soaking section where the critical washing process takes place.
This section is also called the detergent zone where the washing process is carried out by using
caustic (2%) and steam at about 65-80oC. This consists of several identical detergent tanks, the
number of which depends on the type of treatment required. The bottles are washed by the
chemicals in the detergent solution, the temperature, and the mechanical action of the internal
sprays at the exit of the detergent tanks. Soaking may take from 4-6 minutes.
4) Final Rinse
The bottles are now moved to the rinsing area, which consists of a tank and a spraying zone. This
includes 3 recycling internal and external spraying areas and a final internal section where the
bottles are sprayed with clean water. After a pause to allow the water to drain off, the unloading
system places the bottle on the conveyor belt.
The main objective of this section is to:
 Remove the remaining impurities.
 Remove alkalinity (caustic) by adding horolith.
 Reduce temperature.
 Rinse the bottle.
5) Fume extraction
Fume or vapors are removed and conveyed to the exterior. The extraction hood must be used
always during normal operations and for a preset period after switch-off so that all vapors and/or
fumes are removed from the machine. Its operation and timing are controlled by the working
program.

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 Figure 15: Bottle washing machine
The operation of this washer machine is done by using PLC (Programmable Logic Controller)
system. There are different types of sensors that are used as input for this PLC system, these are;
 Inductive sensor; this sensor is used to measure speed control.
 Conductivity sensor; this sensor is used to measure soda levels.
 Level sensor; this sensor is used to measure the level of the added chemicals. This level
sensor in the types of electrode and pressure.
 Flow sensor; this sensor is used to measure the flow of bottles in this machine.
 Pressure Gauge; this instrument is used to measure the amount of pressure.
 Temperature Gauge; this instrument is used to measure the amount of temperature.
EBI (empty bottle inspection)
Machine is electronically inspecting different defects of the bottle, such as:

 Neck of bottle
 Inner-side of bottle
 Base of bottle
 height of the bottle
 Residual liquid
 Caustic inside bottle
When there is detection of Brocken, fallen over, over height or under height occur the machine
stop work or rejected the bottle

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 CIP system
Clean-in-place (CIP) is a method of cleaning the interior surfaces of pipes, vessels, process
equipment, filters, and associated fittings without disassembly. The CIP system is run by a
digital computer called programmable logic controllers (PLCs) which controls the flow,
temperature, and time for the chemical solutions. The cleaning agent solution is circulated
through a circuit of tanks and/or lines to eliminate contaminants or product residues and is rinsed
out with water. Depending on the CIP system, the cleaning agent solution is may flow back to a

reservoir so that they can be re-used or drained immediately after they have been used.

CIP Cleaning Agent Preparation

The process of CIP is carried out by cleaning agents which are prepared in the CIP room. In this
room, the caustic (2%) is allowed to be mixed with water in a tank at an appropriate ratio. Then,
steam is injected through a plate and frame heat exchanger to heat the caustic solution at 80oC.
This solution is stored in two tanks as a reservoir.
CIP steps
The blender CIP process is periodical, which is allowed to run at a time when one beverage type
is produced and completed. This CIP process has steps to be effective and efficient to clean any
contaminants that suffer the quality. The CIP system can be divided into three depending on its
steps of operation or application. These are:
 Normal change over step
 Three steps
 Five steps
Five steps CIP performs every 48 hours and when there is a product change from Fanta
strawberry to another product. Three steps CIP performs when below 48 hours there is any
product change from other coke products to coke. Normal change over CIP is almost the same as
that of 3 step CIP but there is a slight difference between them that is in three-step CIP there is
the circulation of hot water but in normal change over CIP, there is no circulation of hot water
just rinsing with hot water is performed. In three steps CIP mechanical changeover is a must
while in normal change over CIP mechanical changeover is optional, depending on the type of
the previous product. The main difference between the two CIP procedures is that during three-

27
step CIP only disinfection of the filler machine is performed while in five-step CIP both
disinfection and sanitation of the filler machine are performed.
Table 2: CIP steps
CIP Steps Operations
1 Rinsing with cold water
Normal change over 2 Rinsing with hot water
3 Rinsing and emptying the hot water
1 Rinsing with cold treated water to flash previous product
Three steps 2 Disinfection with hot water by circulation
3 Rinsing and Empty the cold water
1 Rinsing with cold treated water to flash previous product
2 Cleaning (sanitizing) with a hot caustic solution
Five steps 3 Rinsing the caustic with cold treated water
4 Disinfection with hot water
5 Rinsing with the cold water

BLENDER/MIXER
Blender is a system for the preparation of final beverages in which the correct quantity of basic
ingredients (water, syrup, and CO2) is measured and dosed in a continuous electronically
controlled process which leads to very high product quality (high precision Brix and CO 2
Volume values) in all operating conditions.
The system consists of:
 Deaerator
 Carbonize
 Blender
 Brix regulator and recorder
 CO2 regulator and recorder
 Finished product storage tank, all installed in a single frame.
The working principle and process

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Sugar is mixed with treated water to give simple syrup (SSA), which is just a highly
concentrated sugar solution and which normally ranges between 60 and 640 Brix. SS is then
mixed with the concentrated product ingredient and some more water. This syrup is carbonated
by either carbonating the treated water before blending it with the syrup or by carbonating the
final blend. This gives it its character and flavor giving final syrup (FS).

The process of converting the prepared final syrup to the final beverage is now the role of the
blender. That is, blending the final syrup with more treated water at an exact blending ratio then
carbonating, finally, this gives the final beverage.
The process of blending/mixing to produce the final beverage that is ready to be sent to the filler
is as the following.
1) De-Aerating Water
The treated water transferred from treated water tank storage that is needed to be mixed is first
de-aerated (removal of air/oxygen) at the de-aerating tank using a vacuum pump. The purpose of
de-aeration is:

 To remove dissolved gases and oxygen from the treated water

 To prevent the growth of algae due to lack of oxygen
 To increase shelf life the beverage
There are two main ways of de-aerating the treated water:
 CO2 Deaerator
 Vacuum pump De-aeration
2) Carbonation
The process of mixing carbon dioxide with treated water (de-aerated) and the final syrup by
applying high pressure is called carbonation. Before adding and mixing CO 2, the final syrup is
chilled or (cooled) by plate and frame heat exchanger to lower temperature, which makes the
CO2 more soluble in the beverage.
Preferring CO2 for the carbonation purposes are:
 Easily dissolvable in water
 The solubility can be readily controlled using pressure and temperature.
3) Blending

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This is the core area at which the final syrup, de-aerated /carbonated water, and CO 2 are get
mixed inline. The carbonated water and the final syrup are first proportionated. This proportion
is different for the different types of beverages going to be filled. For Coca-Cola, the proportion
ratio for blending is 5.4: 1. This means that for 1 volume of final syrup there would be 5.4
volume of carbonated water is needed. Then the total volume of beverage becomes 6.4 volumes.

4) Storing
The prepared beverage in the blending section is stored in a tank as a reservoir for the filling
section/process.

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Figure 17: blender process

31
 FILLER MACHINE
Filler is a machine that fills beverages into containers (bottles). It has fill valves that transfer
the beverage into the container in a way designed to ensure very little agitation and at a
constant rate. The filling system is fully automated and mechanized.

Figure 18: filler machine

It takes the following as input:
I. Beverage: from the blender
II. Pressure: from the air compressor
III. Electrical energy: for drives
IV. Grease: from grease store
V. Water: from treated water tank
Bottle filling machine and design in EABSC
The bottle filling machine in the EABSC DD plant is SIDLE which is built as a rotating machine
with 96 filling valves. The bottles are delivered on a conveyor belt, separated to a predetermined
spacing by a separating device, and positioned on a lifting platform under the filling elements by
a star wheel loading device. The bottle filling machine is built synchronously with the bottle
closing machine (crowner).

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Main component elements of the filling machine
The main components of the filler are described in the following
 The machine frame
 The machine drive
 The product container(CAROUSEL)
 The lifting elements (JACK)and,
 The filling elements

Figure 19: top view of filler machine

The rotor structure part is the most important. It is housed on a ball bearing in the machine frame
and is driven from there. Mounted in front of this is the front table in which the drives from the
bottle feed and removal are installed. These include
 The feed-in screw
 The loading star wheel
 The unloading star wheel etc.
Because the cent rein feed column rotates, the necessarily:-
 Fixed product delivery pipe
 Compressed air for the pneumatic valves and the lifting elements
 Electrical signals for solenoid valves and probes,

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Machine drive
The drive motor moves all the working elements parts synchronously. The rotor of the bottle
filling machine has a high mass and consequently, it also has high angular momentum. For ease
of setting the rotation speed AC motor with a frequency converter is used for the drive. These
auto run-up to the preset speed on starting. Because of the large angular momentum, there would
be a long running period after the machine is switched off. This is undesirable for several
reasons. The drive is therefore equipped with a brake.
Product container (CAROUSEL)
The product tank (carousel) consists of the filling bowl and filling valves, the filling valve
control mechanism, and a fixed section for connection to the drive base. The product container
serves as a storage tank for the product and for supplying it to the filling heads. The filler bowl is
of the annular type and made from stainless steel. The filler bowl cover is bolted down, though
maybe removed for periodic internal inspections. The product feed pipe, CIP piping, the
counter−pressure in feed and outfeed pipes and the product recirculating pipes run out from the
centering feed column to the filler bowl.
Other items mounted on the filler bowl cover include:
 Level probes
 Pressure gauge
 Temperature sensor
Lifting elements (JACK)
The lifting elements serve to press the bottles against the filling heads and thereby provide a
temporary stable connection between the bottle and the filling head. For this, lifting elements are
located below filling heads. The Lifting elements are vertically arranged cylinders that raise the
bottles using lifting matriculates driven by compressed air and pressing them against the filling
heads.
Filling elements of filling valves
The filling heads have a very complicated structure consisting of several different components
which are described individually in the following. They include
 Centering cups
 Filling valves with vent tubes

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 A control for the valves

Figure 20 filling valve

Centering cups
During filling the bottle is raised. To obtain the correct centering of the bottle on the filling
head, an intermediate centering element is fitted which is carried upwards by the bottle being
raised.
FILLING VALVE WITH VENT TUBE
Phase 1 counter pressurizing
First, the bottle is pressed; air-tight against the filler head by the centering cup. As a result of
the actuation of the roller lever, the gas valve is briefly opened and air passes into the bottle
through the vent tube from the filler bowl and purges the bottle. The air flowing in produces
a high air Concentration in the bottle. Simultaneous the pressure in the bottle is raised to the
same pressure as that in the annular bowl.

35
 Figure 21: filling valve with vent tube
Phase 2 filling
After the pressure equalization between the bottle and the filler bowl, the roller lever opens,
via the outer spring, the valve seal. The product can now flow downwards and is deflected by
the deflecting cone against the bottle wall and flows down the wall in a thin film. The air
displaced flows back into the bowl through the air pipe.
Phase 3 end of filling
As soon as the product has reached the bottom of the vent tube it rises in this, by the laws of
physics applying to connected vessels, whilst the gas located above the vent tube can no
longer escape. In this phase, there is a slight overfilling of the bottle which must be corrected
later.
Filler CIP
The quality parameters of the product must remain constant for a very long time. It must be
possible to clean all parts of the filler. For this, rinsing caps are placed under the filling
valves and the cleaning and disinfectant solutions are circulated by pumping through the
chambers and pipes.
The main objectives of CIP are
 To clean(sanitize) the filler machine against product deposits, organic and inorganic
salts, oils, and other materials which are difficult to clean by mechanical cleaning
means.
 To disinfect the filler machine and its component against microbial contamination

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 Figure 22: The filling unit: a sectional view

Crate Conveyor
The conveyor system is the main function of conveying cases and bottles throughout the
Washing, filling and discharge process. Its working principle is electromechanical system in
which all the Induction motors are coupled with the mechanical chains which drive the chain
mechanism in which the upper part of the chain is flat and can carry things that are loaded.

Date Coder
Date coder is a device which is used to write the date of production of the soft
drinks and the expiration Date of soft drinks on the surface of the glass filled with
the soft drinks. To perform this Activity two date coder found both are work
sequentially.

Figure 23: Date Coder

Packer Machine
Products pass through all above processes its finally comes to packer machine the function this
machine is opposite of Un-packer. Packer machine is placed front of un-packer machine and
used to assemble filled bottle (from filler machine) with crates (from crate washer) then finally
discharge through conveyor to temporary storage of products.
Operation modes

1. Automatic operation

2. Semiautomatic operation

37
3. Manual operation

Figure 24: Packer machine

2.4. THE WORK TASK THAT WE HAVE BEEN EXECUTING

We have started our work on March 19/2022 the day we started to meet the plant trainer
called MR. Dereje Shawol gave to us a short orientation about the section of engineering
team sub organizational flow of the section and order to take safety principle by related
person started by giving safety rule: ear protection, safety shoes, and protection cloth. And
directly connect to different maintenance planer and electrical and mechanical line
specialists. So we have been working in this section for three months.
East Africa bottling Share Company has the latest machines which have very good
efficiency. But the company is mainly concerned with how many bottles are filled per day.
Following that they do not much worry about the life and efficiency of their machine. The
used machine and after problem observed on the machine then they threw out. As internship
students, we are interested to redesign machines that maximize productivity but it is difficult
for us to design such complex machines by this problem we are going to analyze and
improve productivity by focusing on employees training.

2.5. THE PROCEDURES USED WHILE PERFORMING THE WORK TASK

During our internship program, it was easy to gain any accesses that help us to collect
information of any machine. Here are some of them:

38
  By direct interview:
It was the first choice to gather information by direct interviewing the operators of the
machine and other concerned people. Operators are the owner of the machine, so that is
better to ask them to know more.
 Participating in maintenance activity
During maintenance, machines are disassembled. This situation was very important for us to
observe components of the machine.
 Data gathering
It is possible to read the manual of every machine that describes the safety and operation of
the machine which is available in the company’s library.

2.6. HOW GOOD WE HAVE BE EN IN PERFORMING OUR WORK TASK

We are always committed to our work and we always present at work other than holidays and
weekends. Although we can say we were good enough to execute our job because it was our
first opportunity for practical work. So we were very passionate to do every kind of work and
developing our knowledge about practical applications. After a month we accomplish some
tasks by ourselves and solve problems. And also, They give us a recommendation letter for
our performance.

2.7. THE CHALLENGES WE HAVE BEEN FACED DURING THE INTERNSHIP

Behind every success, there is /are challenges. Among the challenges we have been faced,
some of them are.
 When we began our internship program the supervisor ordered us to follow the
schedule by observing and asking the operator. But most operators are mechanical so
it is difficult to understand easily the electrical part of the machine and how it is
operating.
 Most operators assume that university students are someone who knows everything
about the machine.
 The factory has very high noise that you could not lesson to each other in the factory,
so it was very challenging to ask the operators of each machine how the machine
works.

39
  Lack of computer and internet access. It was hard to get more written information.
Besides, it was difficult to search more about related things with the production and
my project.

2.8. MEASURE WE HAVE TAKEN TO OVERCOME THE CHALLENGES

We have taken a measurement when the challenge overcomes by:-
 We were using our own shoes until we had been given the safety shoes.
 We have discussed to all team leaders to face problems.
 We were passing our spare time at the smoking area to refresh our mind!
 We have asked the supervisor permission to work on our project.

2.9. Design and construction in terms of safety and economy

The design of the factory highly is intended for the safety of its workers and environment. This
can be seen, for instance, appropriate width of roads for workers; clearance of any harmful
materials and chemicals around working areas since they are stored in separate buildings, and
full safety signage’s.
In terms of the economy, however, has some problems. The most expensive and standard
machines are integrated with another machine that is not. For instance, the washing machine is
the most standard machine that is connected with the boiler operationally. The boiler is standard
as of the washer. Because of this, the durability of the boiler is decreasing from time to time.

40
 CHAPTER THREE
OVERALL BENEFIT OF THE INTERNSHIP
In our overall internship program we can gain the following benefits from the companies
which are:-

3.1. IN TERMS OF IMPROVING PRACTICAL SKILLS

The internship program had a lot of benefits and one of them is improving practical skills.
Practical skills require work performed by hand and using the equipment. East Africa
Bottling Share Company (EABSC) is a vast company that includes a metal workshop,
garage, training room and inventory control(IC), warehouse, etc. We are involved in
engineering workshops whenever there is maintenance, current order for production, or
orders for outside use. We did maintenance and all overproduction in most. Besides, we are
involved with the production area by taking the time delay and to identify the problem which
stopped the machine and we are going to recognize employee's performance. This all helped
us to practice and improve our practical skills.

3.2. IN TERMS OF UPGRADING OUR THEORETICAL KNOWLEDGE

In addition to the practical skills, this internship helped us to improve and develop our
theoretical knowledge. It strengthens our engineering experience and made us appreciate our
academic studies. When faced with a new thing in the company process we have tried to read
more on it by Referring to different manuals of machines and discussing it on the theoretical
aspect. So we have learned the importance of the theory knowledge and its direct effect on
the companies output.
We also upgrade our theoretical knowledge about the academic background of our study. The
main things that we develop here are:
 Understanding and applying the concept of Control the system and production
planning, especially the concept of capacity utilization.
 We understood how the working principle of many machines and equipment.
 Understanding the concept of time study.

41
3.3. IN TERMS OF IMPROVING OUR INTERPERSONAL COMMUNICATION
SKILLS.
The purpose of communication is to get our idea across to others clearly and unambiguously.
Despite its importance, many individuals continue to struggle with this, unable to communicate
their thoughts and ideas effectively – whether in verbal or written format. This inability makes it
nearly impossible for them to compete effectively in the workplace and stands in the way of
career progression. Hence, we are well aware that without improving our communication skills
there is no succession in our internship program. As we are a student it is expected for us to ask
about the workflow and everything and for that, we need to reach out to others in position.
Thanks to all the employees, we were able to communicate with most of them as they made it
easier for us. We also had good interactions with our supervisors as a student and managers. For
most, we were able to make friends with employees. This was all possible by improving our
communication skills.

3.4. IN TERMS OF IMPROVING OUR TEAM PLAYING S KILLS.

Teams need strong team players to perform well. Teams need people who speak up and express
their thoughts and ideas, directly, honestly, and with respect for others and the work of the team.
In our stay, we realized the value of teamwork as the project was achieved with teamwork. While
doing the project our team was arguing and debating over ideas till we agree on one point. This
helped us to know our strengths and weakness in teamwork. Here is a list of what we learned
from teamwork;
 Listening to ideas of others whatever it is.
 Open-minded to another point of view.
 Able to share information freely.
 Able to celebrate the successes and learn the setbacks.
 Understand complaints of others and make sure that the communication channel flow is
free.
 Be flexible rather than rigid for new concepts and changes. With all this, we are confident
to say that we improved our team playing skills.

3.5. IN TERMS OF IMPROVING OUR LEADERSHIP SKILLS

Leadership skill is a critical management skill, which is the ability to motivate a group of
people towards a common goal. We have learned that through patience, persistence, and hard

42
 work, we can be highly effective leaders. We lead the project and sometimes it is hard to
manage a group of people with different thoughts. However, if there is good communication
in between it will be simple. Besides we have been observing the supervisors and managers
around the working area how they perform their leadership. The important points we have
noticed as a leader are as follow;
 Ability to encourage and motivate workers to do their best.
 Ability to communicate with all workers without any force.
 The Ability to listen to problems and focus on their solution.
 To have clear and defined goals missions and vision.
 Be willing to admit and learn from failures and weaknesses.
 Also learns how to solve any problems developed.

3.7. IN TERMS OF IMPROVING ENTREPRENEURSHIP SKILLS

Currently, our country Ethiopia needs skilled and educated human power that can solve and
create a new project related his/her stream to his/her country. The main problem in Ethiopia
is how anyone creates a business of own. The internship program contributes us lot of things
to the entrepreneurial way of thinking and skills. To mention some;
 We know that engineers can work everywhere and can create work by themselves
 It helps us to understand the business concept
 To see and evaluate business opportunities
 To create a high level of achievement motivation
And also participating in this practical world helped us to develop confidence in changing
paperwork into a tangible one. It upgrades our problem-solving skills. Participating in an
internship allows us to gain a better perspective of postgraduate Employment by applying the
principle and the theories we have been developed in the classroom. This practical application
creates an easier transition from the classroom to the working world while participating in this
internship realizes that creativity and problem solving is one of the Starting points of
entrepreneurship.

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 PART TWO

PROJECT
TITLE: FEED WATER HEATING SYSTEM WITH TEMPERATURE AND LEVEL
CONTROL FOR BOILER.

ABSTRACT
This project is concerned with the design and simulation of feed water heating system process
for boiler and to achieve water Level and Temperature control at desired set point value. The
manipulated variables are the pump power, on the water outflow line, and heat supply to the
tank. The main objective of this project is pre heating the feed water of boiler and it is very
important to the boiler. That means increasing the efficiency and life time of the boiler, and also
decreases the required time to generate the steam. And the company minimizes the cost of
energy or consumption of heavy fuel oil. To performing this task the project containing Level
sensor, Temperature sensor and Heater. The function of those elements is, the level sensor
controls the level of the water and temperature sensor control the temperature of water final the
Heater system use to heat the feed water in tank.

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 CHAPTER ONE
INTRODUCTION

1.1. BACKGROUND OF THE PROJECT

Automation describes a wide range of technologies that reduce human intervention in processes.
Human intervention is reduced by predetermining decision criteria, sub-process relationships,
and related actions and embodying those predeterminations in machines. It includes the use of
various equipment and control systems such as machinery, processes in factories, boilers, heat-
treating ovens, switching on telephone networks. [1] Fluid level control is a mechanism, device,
or system that monitors, compares, and regulates the level of liquids or gases within a process to
a set value. Level control is used to adjust the level value to a safe level using electric or
pneumatic signals. [2] To provide good control, accurate measurement is paramount. Level
measurement determines the position of the level relative to the top or bottom of the process
fluid storage tank or silo. Level control and water heating temperature measurement are essential
to assuring the safety and profitability of industrial processes. This Technology Zone offers an
insight into the latest innovations in level control and measurement of fluids.

1.2. Problem Statement

During our internship program at EABSC in DD plant there is steam generation plant that is
implemented with a Thermax fire tube boiler and the main function of boiler is generating the
steam for the several purposes in production room. For this process the boiler need water and this
water is initial cold, so to generate the steam the boiler needs high energy and time, therefore in
order to increase the efficiency, to reduce the required energy and required time of the boiler we
can use heater to increase the temperature of feed water.

1.3. Objectives
1.3.1. General objectives
 The general objective of this project is to design feed water heating system with Level
and Temperature control for boiler using Arduino Uno.

1.3.2. Specific objective

 To design and implement a water pump control and power circuit
 To control the heater to provide the desired temperature of the feed water for the boiler.

45
  To display the level of water in the tank and the Heater temperature range to the operators
easily.
 To construct hardware implementation for the project by using logic state and
temperature sensors.
 To construct hardware implementation for the project by using logic state and
temperature sensors.

1.4. Significance of the project

EABSC in DD plant the boiler use HFO to generate the steam, now a day this fuel oil is highly
expensive in global market (around 120%) , so that we have to use wisely or we have to
minimize the consumption of fuel. Generally this project is very important for this company.
 It helps to minimize the cost by reducing the consumption of energy (HFO).
 Reduce the time required to generate the steam.
 Increase the efficiency of the boiler.

46
 CHAPTER TWO
LITERATURE REVIEW
This literature review describes the past and current researches that have been carried out that are
related to this project. This review investigates numerous aspects of sensors, indicators and the
overall working system of the related to this project.
In January 2008, Cytron Technologies Limited built a commercial Temperature Control System
using 2 LM35 Temperature Sensors. Other components in the system included a PIC16F876A
Microcontroller, LEDs, pump motor and a BD135 power transistor. A difference in the design of
this system over previously designed models by the company was that: in previous versions, the
PIC was used to control the LEDs and Buzzers. In this project, the PIC doesn’t have enough
current to perform this function; hence, an NPN power transistor (BD135) is used for switching
purposes.

47
 CHAPTER THREE
METHODOLOGY
In this chapter block diagram representation of the feed water heating system and its brief
description, flow chart diagram of the system and its algorithms will be discussed.

3.1, BLOCK DIAGRAM

Figure 3.1: Block diagram of water heating system with temperature and level control
The Figure 3.1 above demonstrates the block diagram of the overall system. The system has
temperature sensors, which functions simultaneously to measure the temperature of heating feed
water for the boiler and logic state is used for indication of tank level. Then the input of the
sensor will be sent to the Arduino microcontroller and it receives the input signal from the sensor
and processes them. If the input signal is within the programmed temperature and level range,
the microcontroller will activate the pomp motor to pump the water from softener into feed water
tank for boiler and it activate the heater to heat the water. In this project, the current temperature

48
level and water tank level is displayed on the LCD so that the operators can aware that the
automatic filling and heating system inside the feed water tank for the boiler supply.

3.2, THE COMPONENTS USED IN DESIGNING THIS PROJECT.

 ARDUINO UNO

Arduino is an open Source electronic prototyping platform based on flexible easy to use
hardware and software. It consists of a circuit board, which can be programed (referred to as a
microcontroller), and a ready-made software called Arduino IDE (Integrated Development
Environment), which is used to write and upload the computer code to the physical board. We
are going to use it as the microcontroller for our project. Pins (5V, 3.3V, GND, Analog, Digital,
PWM, AREF). This Arduino board has an ATMEGA328p microcontroller merged in it. It has
32 KB of flash memory of storing code and it also has a 2KB of SRAM and 1 KB of EEPROM.
The Arduino Uno board is shown in Figure 3.2: below.

Figure3.2: Arduino Uno

Table 1: Arduino Uno specification

MICROCONTROLLER ATMEGA328
Operating Voltage 5V
Input Voltage(recommended) 7-12 V
Input Voltage(limits) 6-20 V
Digital Input-Output pins 14( 6 provide PWM output

49
 Analog Input pins 6
DC currents per i/o pin 40 mA
DC current for 3.3V pin 50 mA
Flash Memory 32 KB(ATMEGA328) of which 0.5KB
used by boot loader
SRAM 2 KB(ATMEGA328)
EEPROM 1 KB(ATMEGA328)
Clock Speed 16MHz
Length 68.6 mm
Width 53.4 mm
Weight 25g

 SOLID-STATE RELAY
Normal relays are mechanical relays whereas SSR is not mechanical. SSR uses an opt isolator
mechanism to switch high power loads.

Figure 3.3: Solid-state relay

Like mechanical relays, the SSR provides electrical isolation between two circuits and the opt
isolator (opt coupler) acts as a switch between two circuits. SSR has some advantages over
mechanical relays. They can be switched on with much lower dc voltage and current. SSR can be
switched on with a minimum of 3 volts dc. SSR can control much high power loads than

50
mechanical relays. The switching speed of SSR is much greater than mechanical. Since there is
no mechanical part in SSR, they produce no sound during switching.

 Water pumps
On analyzing the components of our design able to know that there are many types of water
pumps. Each serves a special purpose in home or business .water pumps however, are
responsible for moving water from one level to another level. Currently the main types of water
pumps used are well pumps, sump pumps and printer tanks. Among these, the one which fits to
our project design is the well pump type. In our project the well water pump help to push water
from the softener tank to hot well tank.

Well water tanks are available in various amounts of horsepower

Fig 3.4: An electrical well water pump

 Transistor
Transistors are semiconductors used to amplify an electrical signal or switch an electrical signal
on and off. Often you will need more power to run a component than your Arduino can provide.
A transistor allows you to control the higher power signal by breaking or closing a circuit to the
ground. Combining this higher power allows you to amplify the electrical signal in your circuit.
A transistor circuit has four parts; a signal power source (connects to transistor base), an affected
power source (connects to transistor collector), voltage out (connects to transistor collector), and
ground (connected to transistor emitter). The signal amplifier use of the transistor works the
same way only Signal In and Voltage In are not connected. This disconnection allows the user to

51
send differing values to the base of the transistor. The closer the voltage in value is to the
saturation voltage of the transistor the more electrical current that is allowed through the emitter
to the ground. By changing the amount of electrical current allowed through to the ground you
change the signal value of the signal out. In our project, we use the BC548 NPN transistor for
switching the motor.

Figure 3.5: BC548 transistor

 LM35 TEMPERATURE SENSOR
The LM35 series are precision integrated-circuit temperature sensors, with an output voltage
linearly proportional to the centigrade scale. This sensor is fully rated from -55 ºC to +150 ºC
and with the linear scale factor of 10mV/ºC. It operates from 4 to 30 V, has less than 60 μA drain
current and has low self-heating (0.08 ºC in still air). The control circuitry or the interfacing of
LM35 is easy due to the low output impedance, linear output, and precise inherent calibration.
The LM35 series is available in hermetic to transistor packages, while the LM35C, LM35CA and
LM35D are available in the TO-92 transistor package. The LM35D is also available in an 8 lead
surface-mount small outline package and a plastic TO-220 package.

Figure 3.6: LM35 temperature sensor

52
  LCD (LIQUID CRYSTAL DEVICE)
It is one kind of electronic display module used in an extensive range of applications like various
circuits & devices like mobile phones, calculators, computers, TV sets, etc. These displays are
mainly preferred for multi-segment light-emitting diodes and seven segments. The main benefits
of using this module are inexpensive; simply programmable, animations, and there are no
limitations for displaying custom characters, special and even animations, etc. The operating
voltage of 16×4 LCD is 4.7V-5.3V. It includes four rows where each row can produce 16-
characters. The utilization of current is 1mA with no backlight.
The 16×4 LCD pinout:
 Pin1 (Ground/Source Pin): This is a GND pin of display, used to connect the GND
terminal of the microcontroller unit or power source.
 Pin2 (VCC/Source Pin): This is the voltage supply pin of the display, used to connect the
supply pin of the power source.
 Pin3 (V0/VEE/Control Pin): This pin regulates the difference of the display, used to
connect a changeable POT that can supply 0 to 5V.
 Pin4 (Register Select/Control Pin): This pin toggles among command or data register,
used to connect a microcontroller unit pin, and obtains either 0 or 1(0 = data mode, and 1
= command mode).
 Pin5 (Read/Write/Control Pin): This pin toggles the display among the read or writes
operation, and it is connected to a microcontroller unit pin to get either 0 or 1 (0 = Write
Operation, and 1 = Read Operation).
 Pin 6 (Enable/Control Pin): This pin should be held high to execute the Read/Write
process, and it is connected to the microcontroller unit & constantly held high.
 Pins 7-14 (Data Pins): These pins are used to send data to the display. These pins are
connected in two-wire modes like 4-wire mode and 8-wire mode. In 4-wire mode, only
four pins are connected to the microcontroller unit like 0 to 3, whereas in 8-wire mode, 8-
pins are connected to the o microcontroller unit like 0 to 7.
 Pin15 (+ve pin of the LED): This pin is connected to +5V
 Pin 16 (-ve pin of the LED): This pin is connected to GND.

53
 Figure 3.7: The 16×4 LCD pinout
 Logic state
Logic state is the logical sense, true or false, of a given binary signal. A binary signal is a digital
signal that has only two valid values. In physical terms the logical sense of a binary signal is
determined by the voltage level or current value of the signal, and this in turn is determined by
the device technology. In TTL circuits, for example, a true state is represented by a logic 1,
approximately equal to +5 volts on a signal line; logic 0 is approximately 0 volts. Voltage levels
between 0 and +5 volts are considered undefined.
Since only two logic states, logic 1 and logic 0, are possible, the techniques of Boolean algebra
may be used to analyze digital circuits involving binary signals. The term positive logic is
applied to circuits where logic 1 is assigned to the higher voltage level; in negative logic circuits
logic 0 is indicated by the lower voltage level.

Figure 3.8: Logic state

54
  POWER SUPPLY
Battery and AC source
A 220V single-phase AC supply is used to power the AC motor and the electric heater. DC
batteries are usually the best ones to feed the Arduino and the Solid State relays used in the
project.
 HEATER
Water Heaters offered comes designed and developed using the latest technology support and
find suitability for applications requiring larger wattages. Further, these are also easy to install,
control, and maintain and can be made available in a different selection of sizes and sheath
materials. Some of its features include meeting heating requirements of water, air, and others;
offering efficient working support; option of stainless steel sheath, copper sheath, titanium tube,
safe and efficient working; come with intelligent control mode.
Features:
 Effectiveness
 Compatible and
 Highest efficiency

55
 3.3, FLOW CHART

Figure 3.9: Flow chart of water heating system with temperature and level control

56
3.3.1, Algorithm of the flow chart
Step1: start
Step2: Read value of water level in tank by using logic state and temperature value of water in
tank.
Step3: Microcontroller takes the value of level and temperature from sensor and processes it.
Step4: Microcontroller sent command to motor pump and heater.
Step5: When the level of water in tank is below the 3/4 th, then microcontroller sends the signal to
motor pump ON or the level of water in tank is above the 3/4 th sends the signal to motor pump
OFF.
Step6: if the value of temperature is less than 50 oC and the level of water in tank is above Low
&& below Full the microcontroller sends signal to both heater ON.
Step7: if the value of temperature is >=50oC && <70oC and the level of water in tank is above
Low && below Full the microcontroller sends signal to heater 1 ON and heater 2 OFF.
Step8: if the value of temperature is >=70oC && <85oC and the level of water in tank is above
Low && below Full the microcontroller sends signal to heater 1 OFF and heater 2 ON.
Step9: if the value of temperature is greater than 85oC and the level of water in tank is above
Low && below Full the microcontroller sends signal to both heater OFF.

57
3.4, SYSTEM DESIGN
Proteus Design Suite
The Proteus Design Suite is a proprietary software tool suite used primarily for electronic design
automation. Mainly electronic design engineers and technicians to create schematics and
electronic prints for manufacturing printed circuit boards use the software.

Figure 3.10: over all circuit diagram

3.4.1 Working principle of circuit diagram

58
 CHAPTER FOUR
RESULT AND DISCUSSION

4.1 SIMULATION RESULT

 If the temperature is less than or equal ( <= 50oC) and level is 1/4th and above then Both
heater are ON

 If the temperature is between (50oC and 70oC) and level is 1/4th and above then Heater 1
ON and Heater 2 OFF

59
 If the temperature is between (70oC and 85oC) and level is 1/4th and above then Heater 1
OFF and Heater 2 ON

 If the temperature is greater than or equal ( > 85oC) and level is 1/4th and above then Both
heater are OFF

60
  Even if the temperature is less than 85oC, but if the water level in tank is below 1/4 th Both
Heater will be OFF

4.2 DISCUSSION

61
References
[1] Dipak K. Sarkar, "Flushing of Water Piping System," in Thermal Power Plant, science
direct, 2017.
[2] M. Groover, " Fundamentals of Modern Manufacturing: Materials, Processes, and Systems.,"
(2014).
[3] S. Lyshevski, " Electromechanical Systems and Devices," CRC Press, vol. 2008. ISBN
1420069721., no. 1st Edition.
[4] EABSC, "OPERATIONAL MANUAL FOR THE COCA COLA BEVERAGES AFRICA,
DD PLANT".
[5] ScienceDirect, "Automatic Water Tank Filling System Controlled Using Arduino Based
Sensor for Home Application," Part of the special issue:
[6] EABSC, "Thermax fire tube Boiler, manual, EABSC," CCSabco.

62
Appendix
#include<LiquidCrystal.h>
#include <NewPing.h>
#include <Wire.h>
#define tempsensor A0
LiquidCrystal lcd(10, 9, 5, 4, 3, 2);
int qut=A1;
int hlf=A2;
int low=A3;
int ful=7;
int q;
int h;
int i;
int f;
int t; //motor status flag
int m=0; // motor flag
const int motor = 13;
const int relay2 = 12;
const int relay3 = 11;
int tempstate;

void setup()
{
lcd.begin(16,4);
pinMode(qut,INPUT);
pinMode(hlf,INPUT);
pinMode(low,INPUT);
pinMode(ful,INPUT);
pinMode(motor, OUTPUT);
pinMode(relay2, OUTPUT);
pinMode(relay3, OUTPUT);

63
Serial.begin(9600);
lcd.print("FEED WATER TANK FOR BOILER STATUS");
delay(500);
lcd.clear();
}
void loop()
{
t=digitalRead(motor);
q=digitalRead(qut);
h=digitalRead(hlf);
i=digitalRead(low);
f=digitalRead(ful);
lcd.clear();
if(f ==0 && q ==0 && h ==0 && i ==0)
{
lcd.setCursor(0,0);
lcd.print("_");
lcd.print("_");
lcd.print("_");
lcd.print("_");
lcd.setCursor(5,0);
lcd.print("LOW");
m=1;
}
else
{
if(f ==0 && q ==0 && h ==0 && i ==1)
{
lcd.setCursor(0,0);
lcd.print(char(219));
lcd.print("_");

64
lcd.print("_");
lcd.print("_");
lcd.setCursor(5,0);
lcd.print("1/4th");
m=1;
}
else
{
if(f ==0 && q ==0 && h ==1 && i ==1)
{
lcd.setCursor(0,0);
lcd.print(char(219));
lcd.print(char(219));
lcd.print("_");
lcd.print("_");
lcd.setCursor(5,0);
lcd.print("HALF");
m=1;
}
else
{
if(f ==0 && q ==1 && h ==1 && i ==1)
{
lcd.setCursor(0,0);
lcd.print(char(219));
lcd.print(char(219));
lcd.print(char(219));
lcd.print("_");
lcd.setCursor(5,0);
lcd.print("3/4th");
m=0;

65
}
else
{
if(f==1 && q == 1 && h ==1 && i ==1 )
{
lcd.setCursor(0,0);
lcd.print(char(219));
lcd.print(char(219));
lcd.print(char(219));
lcd.print(char(219));
lcd.setCursor(5,0);
lcd.print("FULL");
m=0;
}
else
{
digitalWrite(motor,LOW);
lcd.setCursor(0,0);
lcd.print("ERROR!");
}
}}
}}
if(t==HIGH)
{
lcd.setCursor(0,1);
lcd.print("Pump ON");
}
else
{
lcd.setCursor(0,1);
lcd.print("Pump OFF");

66
}
if(m==1)
{
digitalWrite(motor,HIGH);
}
if(m==0)
{
digitalWrite(motor,LOW);
}

int tempstate = analogRead(tempsensor);

lcd.setCursor(0, 2);
lcd.print("THE TEMP IS:");
lcd.print(tempstate);
delay(200);

lcd.setCursor(0, 3);
if(tempstate <= 50 && f == 0 && q == 0 && h == 0 && i == 1 )
{
digitalWrite(relay2, HIGH);
digitalWrite(relay3, HIGH);
lcd.setCursor(0, 3);
lcd.print("HEATER 1and2.ON");
delay(500);
lcd.clear();
}
if(tempstate <= 50 && f == 0 && q == 0 && h == 1 && i == 1 )
{
digitalWrite(relay2, HIGH);

67
 digitalWrite(relay3, HIGH);
lcd.setCursor(0, 3);
lcd.print("HEATER 1and2.ON");
delay(500);
lcd.clear();
}
if(tempstate <= 50 && f == 0 && q == 1 && h == 1 && i == 1 )
{
digitalWrite(relay2, HIGH);
digitalWrite(relay3, HIGH);
lcd.setCursor(0, 3);
lcd.print("HEATER 1and2.ON");
delay(500);
lcd.clear();
}
if(tempstate <= 50 && f == 1 && q == 1 && h == 1 && i == 1 )
{
digitalWrite(relay2, HIGH);
digitalWrite(relay3, HIGH);
lcd.setCursor(0, 3);
lcd.print("HEATER 1and2.ON");
delay(500);
lcd.clear();
}
else if (tempstate > 50 && tempstate <=70 && f == 0 && q == 0 && h == 0 && i == 1)
{
lcd.setCursor(0, 3);
digitalWrite(relay2, HIGH);
digitalWrite(relay3, LOW);
lcd.setCursor(0, 3);
lcd.print("HEATER 1 ON&&2 OFF");

68
delay(500);
lcd.clear();
}
else if (tempstate > 50 && tempstate <=70 && f == 0 && q == 0 && h == 1 && i == 1)
{
lcd.setCursor(0, 3);
digitalWrite(relay2, HIGH);
digitalWrite(relay3, LOW);
lcd.setCursor(0, 3);
lcd.print("HEATER 1 ON&&2 OFF");
delay(500);
lcd.clear();
}
else if (tempstate > 50 && tempstate <=70 && f == 0 && q == 1 && h == 1 && i == 1)
{
lcd.setCursor(0, 3);
digitalWrite(relay2, HIGH);
digitalWrite(relay3, LOW);
lcd.setCursor(0, 3);
lcd.print("HEATER 1 ON&&2 OFF");
delay(500);
lcd.clear();
}
else if (tempstate > 50 && tempstate <=70 && f == 1 && q == 1 && h == 1 && i == 1)
{
lcd.setCursor(0, 3);
digitalWrite(relay2, HIGH);
digitalWrite(relay3, LOW);
lcd.setCursor(0, 3);
lcd.print("HEATER 1 ON&&2 OFF");
delay(500);

69
lcd.clear();
}
else if (tempstate > 70 && tempstate <= 85 && f ==0 && q == 0 && h == 0 && i == 1)
{
digitalWrite(relay3, HIGH);
digitalWrite(relay2, LOW);
lcd.setCursor(2, 0);
lcd.print("HEATER 2 ON");
lcd.setCursor(2, 1);
lcd.println("HEATER 1 OFF");
delay(200);
lcd.clear();
}
else if (tempstate > 70 && tempstate <= 85 && f ==0 && q == 0 && h == 1 && i == 1)
{
digitalWrite(relay3, HIGH);
digitalWrite(relay2, LOW);
lcd.setCursor(2, 0);
lcd.print("HEATER 2 ON");
lcd.setCursor(2, 1);
lcd.println("HEATER 1 OFF");
delay(200);
lcd.clear();
}
else if (tempstate > 70 && tempstate <= 85 && f ==0 && q == 1 && h == 1 && i == 1)
{
digitalWrite(relay3, HIGH);
digitalWrite(relay2, LOW);
lcd.setCursor(2, 0);
lcd.print("HEATER 2 ON");
lcd.setCursor(2, 1);

70
lcd.println("HEATER 1 OFF");
delay(200);
lcd.clear();
}
else if (tempstate > 70 && tempstate <= 85 && f == 1 && q == 1 && h == 1 && i == 1)
{
digitalWrite(relay3, HIGH);
digitalWrite(relay2, LOW);
lcd.setCursor(2, 0);
lcd.print("HEATER 2 ON");
lcd.setCursor(2, 1);
lcd.println("HEATER 1 OFF");
delay(200);
lcd.clear();
}
else if (tempstate > 85 && f == 0 && q == 0 && h == 0 && i == 0 )
{
digitalWrite(relay2, LOW);
digitalWrite(relay3, LOW);
lcd.setCursor(0, 3);
lcd.print("HEATER 1&&2 OFF ");
delay(200);
lcd.clear();
}
else if (tempstate > 85 && f == 0 && q == 0 && h == 0 && i == 1)
{
digitalWrite(relay2, LOW);
digitalWrite(relay3, LOW);
lcd.setCursor(0, 3);
lcd.print("HEATER 1&&2 OFF ");
delay(200);

71
lcd.clear();
}
else if (tempstate > 85 && f == 0 && q == 0 && h == 1 && i == 1)
{
digitalWrite(relay2, LOW);
digitalWrite(relay3, LOW);
lcd.setCursor(0, 3);
lcd.print("HEATER 1&&2 OFF ");
delay(200);
lcd.clear();
}
else if (tempstate > 85 && f == 0 && q == 1 && h == 1 && i == 1)
{
digitalWrite(relay2, LOW);
digitalWrite(relay3, LOW);
lcd.setCursor(0, 3);
lcd.print("HEATER 1&&2 OFF ");
delay(200);
lcd.clear();
}
else if (tempstate > 85 && f == 1 && q == 1 && h == 1 && i == 1)
{
digitalWrite(relay2, LOW);
digitalWrite(relay3, LOW);
lcd.setCursor(0, 3);
lcd.print("HEATER 1&&2 OFF ");
delay(200);
lcd.clear();
}
}

72
73