Kidus Mizan@

TINT PREPARATION AND PUMPING TO THE OVERHEAD TANKER CONTROL SYSTEM BASED ON PLC
Acknowledgement
First of all we would like to thanks great fully our god, the almighty and the merciful. Without
his blessing and endorsement this project would not have been accomplished. And then we
would like to express our gratitude to our advisor INS.ASHEBROM for his motivation, advice
and guidance, immense knowledge and constant support. His guidance has helped us throughout
our mini project work. Next we would like to say thank you to electrical and computer
engineering department for his giving the available materials and support ideas for the project
and who shaped us in academically and psychological knowledge and commitment towards
accomplishing this report paper. Thirdly we need to say thank you for Mr.kahsay hagos who is
supervisor of processing department to give us his hand when we did this report in the company.
Last but not the least we would like to thank all our friends and especially our groups for all the
discussions. We have enjoyed their companionship during our work in this semester.
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List of figures
Figure 1.0 background of hosting company..................................................................................................2
Figure 1.1 overall work flow of the company................................................................................................3
Figure 1.2 coats and shirts.............................................................................................................................5
Figure 2.0 seinging and deseizing..................................................................................................................7
Figure 2.1 Stenter Machine..........................................................................................................................10
Figure 2.2 Mercerizing.................................................................................................................................11
Figure 2.3 printing machine.........................................................................................................................14
Figure 2.4 work flow of processing department..........................................................................................14
Figure 2.5 work responsibility and assignment...........................................................................................15
Figure 3.0 pushbutton..................................................................................................................................18
Figure 3.1 solenoid valve.............................................................................................................................19
Figure 3.2 conductive probe level sensors...................................................................................................20
Figure 3.3 on delay timer.............................................................................................................................21
Figure 3.4 dosing pump...............................................................................................................................22
Figure 3.5 PLC conceptual application diagram.........................................................................................23
Figure 3.6 Basic parts of plc........................................................................................................................24
Figure 3.7 Schematic diagram of the control system...................................................................................25
Figure 3.8 General block diagram of the control system.............................................................................26
Figure 3.9 Block diagram of power supply.................................................................................................27
Figure 3.10 Circuit diagram of power supply.............................................................................................27
Figure 3.11 Flow chart of the control system.............................................................................................28
Figure 3.12 ladder diagram of the output PLC............................................................................................29
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List of tables
Table 3.1 power supply of the components that we used...........................................................................27
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Table of Contents
Aknowledgement..............................................................................................................................i
List of figures..................................................................................................................................ii
List of tables...................................................................................................................................iii
Abstract..........................................................................................................................................vii
CHAPTER ONE..............................................................................................................................1
INTRODUCTION TO HOSTING COMPANY...................................................................................1
1.1.Back ground of Almeda textile factory...........................................................................1
1.2. Company mission..............................................................................................................................2
1.3. Company vision...............................................................................................................2
1.4.Raw materials...................................................................................................................2
1.5.Overall work flow of Almeda textile factory..................................................................3
1.5.1. Spinning department....................................................................................................3
1.5.2.Weaving department.....................................................................................................4
1.5.3.Processing department..................................................................................................4
1.6.Main products and services.............................................................................................4
1.7.Customers of Almeda textile factory..............................................................................5
CHAPTER TWO.............................................................................................................................6
OVER ALL INTERNSHIP EXPERIENCE..........................................................................................6
2.1. How we get in to the company........................................................................................6
2.2.Section of the company we have been working.............................................................6
2.3.Machines of processing department...............................................................................6
2.4.Work flow of processing department...........................................................................14
2.5.Duties of processing section of the company................................................................14
2.6.Work responsibility and assignment............................................................................15
CHAPTER THREE.......................................................................................................................16
TINT PREPARATION AND PUMPING TO THE OVERHEAD TANKER CONTROL
SYSTEMBASED ON PLC...........................................................................................................16
3.1. INTRODUCTION.........................................................................................................16
3.2.Problem statement and justification.............................................................................16
3.3.Objective..........................................................................................................................17
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3.3.1.General objective.........................................................................................................17
3.3.2.Specific objective.........................................................................................................17
3.4.Theory and Methodology...............................................................................................17
3.5.Component justification.................................................................................................18
3.5.1.Push button..................................................................................................................18
3.5.2.Solenoid valve..............................................................................................................18
3.5.3. Conductive probe level sensor:.................................................................................19
3.5.4. Chemical tankers........................................................................................................20
3.5.5 On delay timer.............................................................................................................21
3.5.6.Dosing pump................................................................................................................21
3.5.8.Stirrer...........................................................................................................................22
3.6.Definition of PLC............................................................................................................23
3.7.Advantage of PLC..........................................................................................................24
3.8. Schematic diagram of the control system....................................................................24
3.9.General block diagram of the control system..............................................................25
3.10.Power supply.................................................................................................................26
3.11.Flow chart of the control system.................................................................................28
3.12.S7-200 Software............................................................................................................28
3.13.Result and discussion...................................................................................................29
CHAPTER FOUR.........................................................................................................................31
CHALENGES AND OVER ALL BENEFITS....................................................................................31
4.1. Challenges facing in work task.....................................................................................31
4.2. Measures to solve challenges........................................................................................31
4.3.Benefits we gained from the internship........................................................................31
4.3.1.Management skills.......................................................................................................31
4.3.2.Professional skill..........................................................................................................32
CHAPTER FIVE..................................................................................................................33
CONCLUSSION AND RECOMMENDATION...............................................................33
5.1 Conclusion.......................................................................................................................33
5.2.1 Recommendation to the company:............................................................................33
5.2.2 Recommendation to the university............................................................................34
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References......................................................................................................................................35
APPENDIX....................................................................................................................................36
Abstract
This report is written in almeda textile factory it includes the brief history & back ground of the
company this means how the factory is established & with what type of materials were began its
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work & how the raw materials which are brings either from abroad or domestic raw materials are
being changed in to product & what type of steps are used to produce them additionally we
explain how the machines are operate mechanically & electrically in order to perform the desired
task again we describe the working flow all the productive departments include in the factory
particularly for a machine it is called sizing machine which is found in the cutting department
since we have been working in this section therefore we could describe briefly all the working
principles ,working flow procedure & generally how it operate related with mechanical
department & its currently efficiency additionally we can realize how good we have been in
performing our task from the explanation again we include the measures that we have taken in
order to overcome these challenges finally we explain how improving our practical skills,
upgrade our theoretical knowledge ,improving inter personal communication skills & the
knowledge that we gained in terms of entrepreneur ship skill etc.
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CHAPTER ONE
INTRODUCTION TO HOSTING COMPANY
1.1Back ground of Almeda textile factory
Almeda textile factory has officially started or inaugurated since 1993 GC. It is one the EFFORT
(endowment fund for rehabilitation of Tigray) company found in Tigray region, 1000km away
from Addis and 7km from center of Adwa. A textile is important because as we know our
country has a policy which says agriculture led industrialization which mainly aimed at having
company’s which almost probably use agriculture raw materials of which mainly used textile is
main one.
Textile industry is one of the leading labor intensive industries and in our country Ethiopia the
most density populated cities since the date of inauguration where Hadya and Adwa, in addition
Adwa was plenty of water resource, thus Adwa was best fit site selected because of the
aforementioned reasons.
Almeda textile plc is a vertical integrated mill consisting of spinning, weaving, knitting, woven
processing. Knit processing, engineering, woven and knit garmenting. Its design capacity is
capable enough to produce a variety of products and very flexible in charging to any types of
textile yarned fabric made up of 100% cotton and manmade fiber or blends of any ratio.
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Figure 1.0 background of hosting company
1.2. Company mission

The mission state originates from the total customer satisfaction for the value added products
based on R and D supply competitive garment products to our customer maximize owners’
wealth being as corporate citizen and imparting training and human resource development of the
in habitants ensuring sustainable production capability to contribute development of the region as
well as the nation.
1.3. Company vision

Become a best reference and leading textile and garmenting industry and creating a HUB par
excellence in the textile and garment fields in Africa in general and in Ethiopia in particular.
Core values of the company are Customer satisfaction, Reliable, Commitment and good
governance.
1.4. Raw materials

The mill have a variety of inputs in the form of direct materials and auxiliary supplies cotton,
polyester fiber, sizing materials, fabric preparation chemicals, day staffs/chemicals, printing
pigments/chemicals and accessories, as well as finishing chemicals constitute the direct material
inputs. Utilities and auxiliary input such as electricity, water and effluent treatment chemicals
fuel and packaging materials. Used for the proper function of the plant.
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Two types of cotton are required for the production mix. Cotton “A’’ index with staple length of
1.3/32 inch has been used for the production of fabrics of fine yarn counts. Cotton “B” index
with staple length of 1.1/32 used for fabric of coarser yarn counts.
Polyester fiber is required for the manufacture of polyester/cotton blend fabrics. Currently the
company uses polyester fiber with 1.4 denier and 32 mm modulus.
Fabric preparation materials which include desizing, scouring, bleaching agent and mercerizing
chemicals are imported from foreign.
Suppliers of cotton are: OMMO (Gibe site), OMER, middle AWASH, HIWOT at DANSHA in
HUMERA. Polyester suppliers are: Korea, Turkey and China.
1.5.Overall work flow of Almeda textile factory
Figure 1.1 overall work flow of the company
1.5.1. Spinning department

It is the first step in the textile after ginning. The major raw material for spinning is cotton
around 75% and other natural (wool, silk. Sisal etc.) And manual fibers like polyester and
acetate. It is a process of converting bale (raw cotton or polyester) via a number of processes so
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as to produce quality yarns that can further be used as an input to weaving and knitting
department. This department starts from blowing room .In this there are four lines called A, B, C
and D .A line known as ring frame line, B and C lines together form the open end line and d line
is for polyester.
Cotton is fed to the system by unifolic machine whereas polyester is fed to the system using
manual.
1.5.2. Weaving department

It is a process of converting yarns according to the construction supplied by the customer in to
grey fabric that can be farther be used as an input to the processing department.
1.5.3. Processing department

It is the process of changing gray fabric in to a finished product by means of processing
machines, chemical (according there usage), steam, water and other energies. Basically this has
the main aim of removing impurities chemically and mechanically then giving an esthetic
appearance to the fabric.
1.6. Main products and services

Almeda textile mill is capable of producing variety of fabric those are: Home textiles such as a
bed sheet, pillow case, draw sheet and apron. Health care items such as patient gown, overcoat,
scrape slits, trouser and jacket. Work wears such as over all, over coat, jacket and pant. Apparels
such as shirt, denim trouser and chi on trouser, Different kinds of knit wear products such as
basic t-shirt, polo, singlet and mock neck. Canvas, terry towel, dyed and printed fabric
Though it has this much capacity ,it was not able to became profitable since its establishment
rather it has accumulated loses of several years, Almeda has been producing cheap product type
such as bed sheet , sheeting fabric ,poplin fabric and other dyed fabrics at a big volume though
out its whole experience. This was one of the core contribute one of the losses as Almeda was
not able to produce and sell value added products more over it was not able to acquire a skill to
produce selective products which can be competitive at international level.
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1.7.Customers of Almeda textile factory

Guna:Pillow cover and Bedsheet
Messebo:Cap ,Trouser ,Work jacket ,Over all of long sleeve
Altex oromia police & federal police:Workers uniform , shirt,Work trouser
Local :Cap ,Bib trouser
QC-supply:Bib trouse, Short sleeve over all
tigray police:trouser , shirt, long sleeve overall
military of national defence :cap, trouser,shirt
beggali:work jacket & work overcoat
Figure1.2 coats and shirts
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CHAPTER TWO
OVER ALL INTERNSHIP EXPERIENCE
2.1. How we get in to the company
First we ask them by telephone if there is an opportunity acceptance to do our internship there &
they answered us there was an opportunity & we faxed our letter then, after they have faxed back
the acceptance paper. When we reach at company we have had a letter which is given to us by
our department, then they accepted it. After one day they give us an orientation about the
company how to use the company access such us service, working time & other materials. In the
first week we take an ID from the company & we have started our activity as well.
2.2. Section of the company we have been working

We have been staying in processing section of the host while performing our task for four
months. Processing department is one section of Almeda textile factory which a gray fabric is
changed in to a finished product by means of processing machines, chemical, steam, water and
other energies.
2.3. Machines of processing department

Processing department includes the following machines to change the grey fabric in to finished product.
Seinging and Desizing: Seinging is the process of removing protrude fibers by means of
burning whereas Desizing is the process of removing size materials or natural starch and
modified that been applied to the warp trades in weaving department for the strength purpose.
The machine has brutish in both side of the fabric which rotates in the same direction of running
fabric, but at high speed these removes external fluffs from the surface of the fabric and an
erected protruding fabric making them suitable to Seinging. Seinging flame is adjusted in both
side of the fabric to remove or burned off protrude fibers.
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Figure2.0 seinging and deseizing
Parameters of Seinging and Desizing machine:
 Temperature
 Speed of the machine
 Squeezer
 Flame intensity
 Pick up pressure
 Chemical concentration
 Daily capacity of this machine can produce 50000m/16 hours
Seinging and desizing machine includes electrical devices such as:
 Hallow shaft potentiometer, Solenoid valve and Fun motor

 Hallow shaft potentiometer which is used to control temperature
 Solenoid valve is a pneumatic system which operates by a gas pressures
 Fun motor which is used to protect heat of the circuit’s board etc.
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Operation of singeing and Desizing
 Check the order to be processed and segregate from other stocks of the fabric bathing
 Stitch the fabric properly
 Check whether the width and stitching is very important
 Receive the recipe from the concerned boss and prepared chemical solution
 Properly raise the temperature to the solution of 80c
 Check if all motors are functions well
 Adjust all the parameters before running the machines
 Start production run during running
 The machines employer should control everything process if it is going smoothly
 Cover properly the bath after Desizing and take rotation station.
Purpose of Seinging and Desizing
 To increase appearance of the fabric

 To increase smoothness of the fabric
 Clear printed fabric is achieved
 Clear dyed fabric is achieved
Scouring and bleaching: Scouring is the process of removal natural wax fats oils crushed seed
cotton by the alkali treatment, at high temperature the alkali saponfies and ready to remove these
impurities.
Used for alkali wash i.e. NaOH plus detergent ,oil, grace wax plus high temperature ,soap and
glyceryline then soap is soluble in water whereas glycerin is in soluble in water that is why we
add detergent due to this the chemical that were used in this process are : hydrogen ,acetic acid
and optical brighter.
Bleaching: is the process of whitens the fabric by removing other color from it
It includes Process parameters such as:
 Temperature
 Pick up pressure
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 Steaming time
 Speed of the machine
Scouring and bleaching includes electrical devices such as:
 PT100 temperature sensor Tachogenerator

 Level sensor Pressure switch
 Ball float level sensor
 Dosing pumps
 Chemical dosing at the DIP-SAT
 chemical dosing at the impregnator
 Acid dosing at the washing compartment
 filling water valves
 Heating (steam valves)
The capacity of this machine is around 480000m/16 hour.
Mercerizing: It is the treatment of cotton fiber with the solution of NaOH of specific
concentration under control tension alters their molecular orientation, crystal structure and
morphology to increase absorption, tensile strength, extensibility and Luster.
It is used to make for the treatment of cellulose by the using concentric NaOH with high
temperature.
It makes the gray fabric which should be 100% soft and shining.
It includes process parameters such as temperature, tension, and speed and concentration caustic
soda
Stenter machine: Stenter machine is a machine which is used for both mechanical and chemical
finish.
It is used to make fabric comfortable to wear.
It keeps dimension stability by the help of high temperature.
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Figure2.1 Stenter Machine

Parts of stenter:
 Impregnating trough
 Mahlo
 Squeezer
 Exhausted fan
 Chains Dryer chamber:
 Moisture sensor
 J _ box
Parameters of the machine
 Speed of the machine Temperature

 Pander pressure Width setting
Parameters of the machine
 Speed of the machine Temperature

 Pander pressure Width setting
 Chemicals levels Bowing and crossing
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Figure 2.2 Mercerizing

Washing machine: Washing machine is used to for removing caustic after mercerization and
unfixed dyes fabrics.
It includes Parameters such as:
 Temperature not less than 90OC

 Speed=30-40m/min
 Squeezing pressure
Parts of washing machine
 Guide rollers Over spray

 Squeezer
 Dancer
 Chamber
 Heat exchanger
 Centering device
 washing compartment
 Control board
 Temperature sensor
Duets and procedures of working
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 Clean the machine

 Fill water to the compartment
 Set parameter
 Raise temperature to 90 OC
 Stitch the fabric
 Start production after razing temperature
Dryer machine: It is used to remove water from the fabric. The dryer machine uses steam or hot
air in drying equipment and it includes process parameter speed 50-60m/min and temperature 70
or 80OC
Sanforizing machine: This machine is used for processing of cotton fabrics between them have
the tendency to shirk after washing. It includes process parameters such as:
 Temperature: it is not measured but estimated to be 100-180 OC

 Speed of the machine: speed of the machine must be 400m/min.
 Pressure, tension and shrinkage percentage: It differs depending on the
nature of the fabric.
Parts of Sanforizing Machine are:
 Steaming unit (1)

 Chain (3)
 Cylinder iron (4)
 Blanket (6
 Cylinder drum (7)
Cold pad batch dying: It is used for cotton dying.
The parameters of cold pad batch dying are:
 Temperature
 Pressure
 Speed
 Color viscosity
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Parts of cold pad batch machine are:
 Guiding roller padding through

 Squeezer Control board
 Dosing pump Batching roller
Dryer: It is used to dry the fabric. The process parameters in this machine are temperature and
tension
Its capacity is 40-60m/min.
Printing machine : This parts of processing used to make different designs of the product textile
printing utilizes the same principle of specific dye classes having selected fiber affinities and the
general fast characteristic apply equally to printing as to dyeing .the pigments must be thickened
with gums to prevent from flowing of the print design.
Almeda textile uses screen printer from the three methods of printers .the screen is prep aired
according the design needed for the customer.
The essential ingredients for printing
 Pigment or dyes
 Thickeners
 Binder or fixer
 Cross linkers and rotary printing machine
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Figure 2.3 printing machine
2.4. Work flow of processing department
Figure 2.4 work flow of processing department
2.5.Duties of processing section of the company

 Perform final finishing and controlling the output
 Ensuring that all goods are purchased conforms to the quality of goods ordered and that
the correct quantities are received and recorded before they are put in to stock.
 Ensure that all materials issued are correct for the product
 Ensure that finished goods are of consist ant quality standard and that measurements with
in tolerance laid down in the customer satisfaction etc.
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2.6. Work responsibility and assignment
Figure 2.5 work responsibility and assignment
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CHAPTER THREE
TINT PREPARATION AND PUMPING TO THE

OVERHEAD TANKER CONTROL SYSTEMBASED ON
PLC
3.1. INTRODUCTION
The importance’s of automation at ALTEX factory tint preparation and pumping to the overhead
tankers have increased with the development of technology and control system requirements.
The objective of this project is to prepare a tint by PLC control system and pumping tint to the
overhead tankers automatically. The tint is prepared in the lower tanker and pumping to the
overhead tankers after the first step completed. Components such as manual valves, stirrer motor,
dosing pump, chemical tankers and electrical devices such as relay, sensors, contactor, push
button and breakers are used for complete operation of the control system but, it has a lot of
problems such as no over flow control system, no specified time to stir the chemical with water
exact amount of acetic acid, wetting agent detergents, wall soft, soda ash and silages is not mixed
with water. Indirectly those problems has been resulting other problems like; selvedge tear,
width variation, un-required finish, unevenness tint and different spots was occurred. To solve
this problem we are used automatic control system by the help of PLC operation.
3.2. Problem statement and justification

ALTEX factory do not have automatic tint preparation process and this initiate us to prepared
tint and pumping to the overhead tankers automatically by PLC software. Less /over tint fabric:
manual preparation of tint leads to over tint or less tint, hence the fabric to be stented in the
stenter machine is produced with different spot, un evenness tint and un required finishing tint
over flow: since there is no automatic level control system, the tint is overflowed from the
overhead tankers.
The main problem this project is:
 Man power: since the tint is prepared manually, it needs large man power.
 Health problem: Acetic acid, wall soft, stabilizer and hydrogen peroxide are used for the
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 Preparation of tint; hence the operators are suffered from disease when prepared it
manually.
 Wastage of chemicals: the chemicals are wasted when it is pulled up.
3.3. Objective
This project has both general and specific objective
3.3.1. General objective

PLC based tint preparation and pumping to the overhead tanker control system.
3.3.2. Specific objective

 Implementing the application of PLC
 To increase quality of the fabric
 To prepared a tint by PLC control system
 To cope up the problems such as selvedge tear, unevenness tint and different spot
 To control over flow and run dry
 To minimize man power
3.4. Theory and Methodology

The components of PLC based preparation of tint and pumping to the overhead tanker with over
flow control system are: Input components, output components and Processor. To draw the flow
chart we used PLC s7-200 software, to understand the problem by looking ourselves.
PLC Input components: PLC input components refers to the devices and transducers which are
entrusted with taking in information about the physical world to the PLC. Keep in mind that it
also refers to the PLC hardware that connects to those devices, sensors and transducers. The PLC
uses this input information to make decisions based upon its program whether to energize and
de- energize the outputs controlled by the plc. In our project, electrical devices such as
conductive probe level sensor and push buttons are used as input component.
PLC output components: PLC output components are the control circuits of the PLC also refers
the devices controlled by the PLC devices such as stirrer motors, pump motor and solenoid
valves etc. are the output devices of PLC devices called actuators converts the electrical signal of
the PLC to the physical movement for instance, a valve solenoid stoke or a motor. There are two
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types of outputs: digital output and analog outputs. Some examples of digital outputs are motors,
solenoid valve and lighting etc. analog outputs are for variable level or range output between off
or stopped and on or full speed as for an electric motor for example variable frequency derive.
We use stirrer motor, pump motor and solenoid valve as an output components in our project.
3.5. Component justification

3.5.1. Push button: A push button switch is a small, sealed mechanism that completes an
electric circuit when you press on it. When it's on, a small metal spring inside makes contact with
two wires, allowing electricity to flow. When it's off, the spring retracts, contact is interrupted,
and current won't flow. The body of the switch is made of non-conducting plastic.
Figure3.0 pushbutton
3.5.2. Solenoid valve: a solenoid valve has two main parts: the solenoid and the valve. The
solenoid converts electrical energy into mechanical energy which, in turn, opens or closes the
valve mechanically. A direct valve has only a small flow circuit, shown within section E of this
diagram. In this project, a diaphragm piloted valve multiplies this small pilot by using it to
control the flow through a much larger orifice.
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Figure3.1 solenoid valve
3.5.3. Conductive probe level sensor:

Conductive level sensors are ideal for the point level detection of a wide range of conductive
liquids such as water, and is especially well suited for highly corrosive liquids such as caustic
soda, hydrochloric acid, and similar liquids. For those conductive liquids that are corrosive, the
sensor’s electrodes need to be constructed from titanium or 316 stainless steel and insulated with
spacers, separators or holders of ceramic, polyethylene and Teflon-based materials. Depending
on their design, multiple electrodes of differing lengths can be used with one holder. Since
corrosive liquids become more aggressive as temperature and pressure increase, these extreme
conditions need to be considered when specifying these sensors.
Conductive level sensors use a low-voltage, current-limited power source applied across separate
electrodes. The power supply is matched to the conductivity of the liquid, with higher voltage
versions designed to operate in less conductive (higher resistance) mediums. The power source
frequently incorporates some aspect of control, such as high-low or alternating pump control. A
conductive liquid contacting both the longest probe (common) and a shorter probe (return)
completes a conductive circuit.
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Conductive sensors are extremely safe because they use low voltages and currents. Conductive
probes have the additional benefit of being solid-state devices and are very simple continue to be
conductive. If buildup insulates the probe from the medium, it will stop working properly. A
simple inspection of the probe will require an ohmmeter connected across the suspect probe and
the ground reference to install and use. In some liquids and applications, maintenance can be an
issue.
Figure3.2 conductive probe level sensors
3.5.4. Chemical tankers: Chemical tanks are storage containers for chemicals. They come
in a variety of sizes and shapes, and are used for static storage, processing, mixing, and transport
of both raw materials and finished chemical products. A chemical tank-vessel is of necessity,
designed for a specific chemical, as all chemicals have variable corrosion potentials there are no,
one size fits all. The chemical and application parameters should design tank-vessel.
3.5.5 On delay timer: With an on-delay timer, timing begins when voltage is applied. When
the time has expired, the contacts close — and remain closed until voltage is removed from the
coil. If voltage is removed before time-out, the time delay resets.
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Figure 3.3 on delay timer
3.5.6. Dosing pump: Dosing pumps are low-volume pumps with controllable discharge rates
that are used to inject additives or difficult-to-mix fluids into mixing, pumping, or batch/tank
systems. Dosing pumps are usually made from plastic, thermoplastic, or stainless steel and
feature mounting holes or accessories. Dosing pumps often have a controller which enables the
fluid flow to be monitored and adjusted easily. Dosing pumps can operate based on the principles
of dynamic pumps or positive displacement pumps depending on the design. Dynamic pumps
produce a variable flow suited for generating high flow rates with low viscosity fluids, while
positive displacement pumps produce a constant flow suited for producing high pressures (and
low flow rates) with high viscosity fluids. Most dosing pumps are positive displacement pumps,
which provide steady, low flow for a variety of types of media.
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Figure 3.4 dosing pump
3.5.7. Stirrer: It is a model 300 motorless magnetic that operates by generating a rotating
electromagnetic field in the string heads. The liquid to be stirred has magnetised stirring bar
placed in it.The bar and therefore the liquid, is rotated by the magnetic field produced in the
heads.It provides great flexibility for use with different sizes and types of vessles ,it is practically
suitable for small specialised sample holders frequintly used in electrochemical and spectrometic
applications.
The magnetic stirrer has several advantage over conventional motor driven stirrers. The stirring
heads produce less electrical than motor type stirrers. With no moving parts they are very
reliable. Multiple heads can be connected to a single magnetic stirrer control box all string at the
same speed .Strring head size is not constrained by motor sizes.
3.6. Definition of PLC

A digital electronic device that uses a programmable memory to store instruction and to implement
function, such as logic, sequencing, timing, counting and arithmetic in order to control machines and
processes, The term logic is use primarily concerned with implementing logic and switching
operations .Input devices e.g. switches, and output devices e.g. motors, being controlled are
connected to the PLC and then the controller monitors the inputs and outputs according this program
stored in the PLC by the operator and so controls the machine or process. Originally they were
designed as a replacement for hard-wired relay and timer logic control systems. PLCs have the great
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advantage that it is possible to modify a control system without having to rewrite the connections to
the input and output devices.
Figure 3.5 PLC conceptual application diagram

Basic parts of PLC
All programmable controllers contain a CPU, memory, power supply, I/O modules, and
programmable devices. Basic parts of the PLC are as follows:-
 Processor
 Input/output device
 Power supply
 memory
 Programming panel or unit
23
Figure 3.6 Basic parts of plc
3.7. Advantage of PLC

 High reliability
 Simplifies changes
 Flexible control
 Minimal space requirements
 Higher level of performance
 Higher quality products
 Multifunctional capability
 Software timers/counters - Eliminate hardware
 Easily changed presets
 Software control relays
3.8. Schematic diagram of the control system
24
Figure 3.7 Schematic diagram of the control system

the above symbols are represents as fellow:
 Q1= solenod valve 1 i1= push button

 Q2= dosing pump 1 i2= conductive probe level sensor 1
 Q3= stirrer i3= conductive probe level sensor 2
 Q4=dosing pump 2
i4= magnetic float level sensor 1
3.9. General block diagram of the control system
25
Figure 3.8 General block diagram of the control system
3.10. Power supply

PLC based tint preparation and pumping to the overhead tankers with overflow control system
includes electrical devices such as: stirre motor,dosing pump,solenoid valve ,magnetic float level
sonsor and conductive probe level sensor for the full working of the project. The table below
shows the power supply for the input devices and output devices of the plc. Both DC and AC
power supply are used for the complete work of the project. The power of the plc is 5v dc.
Table 1.0 power supply of the components that we used
Input device Power supply
Conductive probe level sensor 24V DC
Output device Power supply
Stirrer motor 240 V AC
Dosing pump 380V AC
Solenoid valve 24V AC
26
Ac supply is converted into dc suppply in order to feed for the Dc components of the control
system.The following block diagram shows the regulated power supply and regulated circuit
diagram for the power supply.
Figure 3.9 Block diagram of power supply
Figure 3.10 Circuit diagram of power supply
27
3.11. Flow chart of the control system
Figure 31 Flow chart of the control system
3.12. S7-200 Software

The S7-200 series is a line of micro-programmable logic controllers (Micro PLCs) that can
control a variety of automation applications. Compact design, low cost, and a powerful
instruction set make the S7-200 controllers a perfect solution for controlling small applications.
The wide variety of CPU sizes and voltages, and the windows-based programming tool, give you
the flexibility you need to solve your automation problems.
28
3.13. Result and discussion

3.13.1. Result: Our project has a result which is designed using plc S7-200 software. We have
the system using both ladder diagram and function block diagram for its effective functioning
and simulation. The out puts are shown with flashing lights which symbol by later Q.
Figure3. 4 ladder diagram of the output PLC
29
3.13.2.Discussion: The plc controls the output devices by recievng signal from the input devices
such as magnetic float level sensor for run dry protection and over flow of tint,push button and
conductive probe level esnsor according the program stored in the processer using S7-200
software ladder diagram the output from the processer is changed in to electrical form by the
output module of the plc. The LED in the input module and output module indicates the status of
input devices and output devices respectivelly.
Our project consists one bush button, two conductive probe level sensors,six magnetic float
level sensors and three tankers that are two lower tankers and one overhead tankers .The first
tanker holds chemical to be mixed with water in the second lower tanker . It is specified with
volume 100 litre.The second lower tanker and the one overhead tankers are specified with
volume 250 litre.To start the operation the operator should first adjust the required volume of
chemical and water to mixed together in the second lower tanker using adjustable level sensor .
When the required quantity of water and chemical is adjusted ,push button one is pressed to shut
water in to the second tanker .
After the required volume of water is obtained the condutive probe level sensor two changes its
state to turn off the valve one and to turn on the dosing pump to pump required chemical to be
mixed with water.After the required amount of chemical is pumped ,stirrer motor starts to stirr
water with chemical.when the time setted is finished the stirrer motor turns on and dosing pump
two starts to pump the tint to the overhead tankers by recieving the conditions of upper sensors.
When the high level sensors in the overhead tankers give signal to plc the dosing pump two
turns on or off according the program stored in the plc using ladder diagram
30
CHAPTER FOUR
CHALENGES AND OVER ALL BENEFITS
4.1. Challenges facing in work task
We have faced so many problems in our staying in the internship time. Some of the difficulties
are:
Site language- when we joined in to the project the name of woven processing material made us
confusion.
Work flow- since our site is too vast one worker (employee) can work in many or more than one
works. This make us confused to separate the workers to communicate with us or to help us by
their profession.
4.2. Measures to solve challenges

As we mentioned the challenges above, we were faced with a lot of challenges; we had look
alternatives to solve them. To solve these problems or challenges we have taken the following
measures.
Regarding to site language we decide to create a good relationship with the daily workers of the
department. All things are simple to know on process after a time, to know the work task of each
employees we decided to arrange a program that meets with the employee for each then the
problem was solved and they are volunteer (responsible) to accept our program, the challenges
regarding to experience as explained above we have good friend ship with all the workers or
employees, so it helps to build a confidence and to communicate with us freely, at that time we
get a good experience from the employee and from the skilled persons. Generally most of the
challenges were solved through our effort after hard working.
4.3. Benefits we gained from the internship

4.3.1. Management skills
We have gained skills such as: management skill, practical or technical skill, professional skill
and communication skill from the internship.
 Management skill: during the internship we gained management skills such as;
31
 Establishing process and structure,

 Build trust and good relationship between team members
 Resolve conflicts, swiftly if they occur, provide support, especially to those team
members who are less secure.
 Remain positive and firm in the face of challenges to your leader ship or to the team goal.
 Delegate tasks and as far as possible.
 Identify the stage of development that our team etc.
4.3.2. Professional skill

We got the key knowledge and skill which make our profession unique involves the following
terms, those are:
 Organization knowledge and information

 Knowledge and information management
 Using and exploiting knowledge and information
 Research skills
 Information governance and compliance
 Collection management and development
 Customer focus, service, design and marketing
4.3.3. Technical skill
During the internship time we gained practical skills such as reading industrial manual to
identified when problem occurred ,rewinding squirrel cage induction motor and have been
working both as operator and technician in the processing department of the host.
We capable to install home and industry identified industrial problems and solving them.
4.3.4. Communication skills
It is how well we communicate with someone & how well we behave or carry yourself or
simply which means interpersonal skills are how people relate to one another. As an
illustration, it is generally understood that communicating respect for other people or
professionals within will enable one to reduce conflict & increase participation or assistance
in obtaining information or completing
32
CHAPTER FIVE
CONCLUSSION AND RECOMMENDATION
5.1 Conclusion
This prototype is specifically designed for the accurate mixing of water with chemical and
pumping to the overhead tankers with over flow control system. Different tints can be prepared
once the first tint is prepared and pumped but, it is not possible to prepared different tint types at
the same time .The adaptability in industry of our research is due to its PLC based process. It is
more probable that our research is accepted due to ease of usability and very low cost. In today
world industry can grow by making them advance in technology and by up grading their
machineries and plants. This project apply this good idea that is, it uses the old tankers that found
in Almeda textile by adding some electrical materials that are crucial for effective work of the
system.
Generally, internship provides us with valuable insights into the professional and industry
oriented side of our field of study .It enable us to put into practical skill, techniques and
knowledge that are important for our success in our future work place. It also helps us to identify
title for our final project work.
5.2Recommendation
We have recommended for the company as fellow:
5.2.1 Recommendation to the company:

Almost the control system in Altex is relay hardware technology so it should replace with plc as
much as possible. Since, Altex is a large hosting company; it should provide different services
for the students who spend their internship period for the purpose of sharing experience and
skills. Over coat during the working hours and should give certificate for the new thing; they
create and solve problems.
33
5.2.2 Recommendation to the university

In order to amend or improve students’ practical skill, our university has to create industrial
linkage and it should have a work shop in the hosting company. Advisors must available in the
company to coordinate the students during the internship time, but during our internship time no
advisor came in to the hosting company.
34
References
[1] Birbir, Y. and No gay, H. S. (2008). Design and Implementation of PLC-Based Monitoring
Control System for Three-Phase Induction Motors Fed by PWM Inverter. International Journal
of Systems Applications, Engineering & Development, 2, 128-135
[2] Bolton, W (2006). Programmable Logic Controllers 4th ed , North Carolina and Elsevier
Newness.
[3] Halo, L. and Ruling, P. (2005). Application of Centralized PLC Automation Control in Painting Line
of Steel Plant. Proceeding of the 4th Asian Conference on Industrial Automation and Robotics, Landmark
Hotel, Thailand
[4] Hugh, J (2008). Automated manufacturing system with PLC Version 5.1
[5] James, H. (1993). Industrial control electronics, James Humphries, Delmar Cengage
Learning; 4th edition
[6] PLC s7-200 software MICRO Instruction manual Siemens
35
APPENDIX
 EFFORT:Endowment fund for rehabilitation of Tigray
 PLC: programmable logic controller
 Plc: privet limited company
 ALTEX: Almeda textile factory
 Unifolic: sack the lots of cotton and distribute to
 Uniclean: clean the dirt on the cotton.
 Unimix: mix, clean and open the cotton.
 Uniflex: make the cotton flexible and soft condenser
 PT 100: senses change in temperature
 Jigger, loop steamer, loop former, cold pad batch
 DGM: department of general manager
 HR: human resource
 ATC: advanced training center
36

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TINT PREPARATION AND PUMPING TO THE OVERHEAD TANKER CONTROL SYSTEM BASED ON PLC

Figure 1.0 background of hosting company

1.2. Company mission

1.3. Company vision

1.4. Raw materials

1.5.Overall work flow of Almeda textile factory

Figure 1.1 overall work flow of the company

1.5.1. Spinning department

1.5.2. Weaving department

1.5.3. Processing department

1.6. Main products and services

1.7.Customers of Almeda textile factory

Messebo:Cap ,Trouser ,Work jacket ,Over all of long sleeve

Altex oromia police & federal police:Workers uniform , shirt,Work trouser

Local :Cap ,Bib trouser

QC-supply:Bib trouse, Short sleeve over all

tigray police:trouser , shirt, long sleeve overall

military of national defence :cap, trouser,shirt

beggali:work jacket & work overcoat

Figure1.2 coats and shirts

2.2. Section of the company we have been working

2.3. Machines of processing department

Figure2.0 seinging and deseizing

Parameters of Seinging and Desizing machine:

Seinging and desizing machine includes electrical devices such as:

 Hallow shaft potentiometer, Solenoid valve and Fun motor

Operation of singeing and Desizing

Purpose of Seinging and Desizing

 To increase appearance of the fabric

It includes Process parameters such as:

Scouring and bleaching includes electrical devices such as:

 PT100 temperature sensor Tachogenerator

The capacity of this machine is around 480000m/16 hour.

It is used to make fabric comfortable to wear.

It keeps dimension stability by the help of high temperature.

Figure2.1 Stenter Machine

Parameters of the machine

 Speed of the machine Temperature

Parameters of the machine

 Speed of the machine Temperature

Figure 2.2 Mercerizing

It includes Parameters such as:

 Temperature not less than 90OC

Parts of washing machine

 Guide rollers Over spray

Duets and procedures of working

 Clean the machine

 Temperature: it is not measured but estimated to be 100-180 OC

Parts of Sanforizing Machine are:

 Steaming unit (1)

Cold pad batch dying: It is used for cotton dying.

The parameters of cold pad batch dying are:

Parts of cold pad batch machine are:

 Guiding roller padding through

Its capacity is 40-60m/min.

The essential ingredients for printing

Figure 2.3 printing machine

2.4. Work flow of processing department

Figure 2.4 work flow of processing department

2.5.Duties of processing section of the company

2.6. Work responsibility and assignment

Figure 2.5 work responsibility and assignment

TINT PREPARATION AND PUMPING TO THE