Temicho New1

DTU/FOT/ECE- ICS/2009 EC
Declaration
I, the undersigned, declare that this Internship Report is my original work, has not been presented
for accomplishment of Internship Report in this or any other University, and all sources of
Materials used for the Internship Report have been fully acknowledged.
Name: Signature: Date:
Temesgen Ermias
Place: Hawassa
Date of Submission: March 13, 2017
This Internship Report has been submitted for examination with my approval as a university
mentor.
Mentors Name:
Signature:
Date:
INTERNSHIP REPORT BY TEMESEGEN ERMIAS Page i

Acknowledgment
I take this opportunity to our profound sense of gratitude and respect to all those who helped us
throughout this internship period. I would like to express my gratitude to Mr. Tebebu. For
guidance and support throughout this internship period. He has been a constant source of
inspiration for me throughout the period of the work. I also want to give gratitude for my
mentors in the company, I consider my selves extremely fortunate for having an opportunity to
learn and work under the supervision of Mr. Abera and Mr. Engda the head of spinning and
substation department respectively in the HTSC.
INTERNSHIP REPORT BY TEMESEGEN ERMIAS Page i

Executive Summary
My final report included brief history of the company, organizational structure, work flow, row
materials, suppliers and customers, products, mission, vision, objectives of the company, project
tasks and overall sections: - spinning section, weaving section and finishing section. From the
report I have also included different types of machines such as:-Bale Plucker, Auto Mixer, Six
step Pitter, Horizontal opener, Card machine, Drawing Frame, Roving Frame, Ring frame, Open
End machine, Winding machine, Twister and Doubler machine, Warping and Sizing machines,
Looming machine, Drafting machine and Inspection machine including their operation and
function.
Lastly, I also describe overall control plant of the company, which includes PLC (programmable
logic control) & relay logic system and some basic electrical devices such as-, sensor, contactor,
relay, rectifier, inverter and fuses are briefly discussed. This internship experience helps me to
improve lot of skills like practical, communication and team playing skills, also to understand
some work ethics.
INTERNSHIP REPORT BY TEMESEGEN ERMIAS Page ii

Table of Contents
Acknowledgment .......................................................................................................................................... i
Executive Summary ...................................................................................................................................... ii
List of Figures ............................................................................................................................................... v
List of Tables ............................................................................................................................................... vi
List of Abbreviations .................................................................................................................................. vii
1. BACK GROUND OF HAWASSA TEXTILE SHARE COMPANY ...................................................... 1
1.1 History of the company ......................................................................................................... 1

1.2 Main Service of the organization .......................................................................................... 1
1.3 Objectives of the Internship .................................................................................................. 8
1.4 Scope of the Project............................................................................................................... 8
2. PROJECT AND CONTRIBUTION ........................................................................................................ 9
2.1 INTRODUCTION ................................................................................................................. 9

Waste water treatment based on PLC ........................................................................................................... 9
2.2 Objective ............................................................................................................................. 10

2.2.1 General objective .......................................................................................................... 10
2.2.2 Specific objective ......................................................................................................... 10
2.4 Methodology ....................................................................................................................... 15
2.5 Literature Review ................................................................................................................ 16
2.5.1 Background ................................................................................................................... 16
2.5.2 Previous Reports ........................................................................................................... 17
2.5.3 Sources and Types of Waste ......................................................................................... 17
2.5.4 Waste water characteristics .......................................................................................... 18
2.6 The existing wastewater treatment with comparison the modified wastewater treatment .. 18
3. INTERNSHIP EXPERIENCE .................................................................................................. 20
3.1 Getting and Visiting the Company ...................................................................................... 20

3.2 Working Sections ................................................................................................................ 20
Overall System Components and Operations of the Company ............................................. 20
Spinning Department ............................................................................................................. 20
INTERNSHIP REPORT BY TEMESEGEN ERMIAS Page iii

Sections in spinning department ............................................................................................ 21

7. Twisting and Doubling ...................................................................................................... 26
8. Open Ending Machine ....................................................................................................... 27
1. ON/OFF (cycling) control .............................................................................................. 38
3.3 Tasks Performed During the Internship Period ................................................................... 39
3.4 Procedures used to perform different tasks ......................................................................... 44
4. THE OVERALL BENEFIT THAT GAINED FROM THE INTERNSHIP ........................................... 46
4.1 In terms of improving our practical skills ........................................................................... 46

4.2 In terms of up grading theoretical knowledge ..................................................................... 46
4.3 In terms of improving inter personnel communication skills ............................................. 47
4.4 In terms of improving team playing skill ............................................................................ 47
4.5 In terms of leadership skill .................................................................................................. 48
4.6 In terms of understanding about work ethics related issue ................................................. 48
4.7 In terms of improving entrepreneurship skills .................................................................... 48
4.8 Challenges I have faced while performing our work tasks ................................................................... 49
4.9 Measurements taken to overcome these challenges ............................................................ 49

5. CONCLUSION AND RECOMENDATION ......................................................................................... 50
5.1 Conclusion........................................................................................................................... 50
5.2 Recommendation ................................................................................................................. 51
Reference .................................................................................................................................................... 53
INTERNSHIP REPORT BY TEMESEGEN ERMIAS Page iv

List of Figures
Figure 1.1 Overall organization and structure of the company ...................................................... 5
Figure1. 2 Overall work sections of the company .......................................................................... 6
Figure2. 4 Simple closed loop controls......................................................................................... 11
Figure2.5 Timer block diagram .................................................................................................... 12
Figure2. 6 Siemen PL S7-300 ....................................................................................................... 13
Figure2.7 Basic components of PLC ............................................................................................ 14
Figure2. 8 General block diagram of the controller and input output interface ........................... 14
Figure2. 3 General process block diagram of waste water treatment ........................................... 16
Figure3. 9 Process of spinning section ......................................................................................... 21
Figure3. 10 Bale plucker .............................................................................................................. 22
Figure3.11 Carding machine ......................................................................................................... 23
Figure3.12 Drawing machine........................................................................................................ 24
Figure3.13 Roving frame .............................................................................................................. 24
Figure3.14 Ring frame .................................................................................................................. 25
Figure3. 15 Winding machine....................................................................................................... 26
Figure3. 16 Twisting and doubler machine .................................................................................. 26
Figure3.17 Open ending machine ................................................................................................. 27
Figure3.18 Yarn store ................................................................................................................... 27
Figure3.19 Process flow of weaving section ................................................................................ 28
Figure3. 20 Warping machine....................................................................................................... 29
Figure3. 21 Sizing machine .......................................................................................................... 30
Figure3. 22 Contactor parts........................................................................................................... 34
Figure3. 23 Fuse parts ................................................................................................................... 35
Figure3. 24 Steam boiler in HTSC .............................................................................................. 38
Figure3. 25 Direct on-line starting method ................................................................................... 40
Figure3. 26 Forward reverse ......................................................................................................... 41
Figure3. 27 Control diagram of star delta starter .......................................................................... 42
Figure3. 28 Power diagram of star delta starting .......................................................................... 42
Figure3. 29 Dynamic break.......................................................................................................... 43
Figure3. 30 Control and power circuit of 3 stages sequential control. ........................................ 44
INTERNSHIP REPORT BY TEMESEGEN ERMIAS Page v

List of Tables
Table 1.1Supplier of main inputs and distances from factory ........................................................ 7
Table1. 2 Port and their distance from factory ............................................................................... 7
Table2. 3 Comparison of the existing with modified waste water treatment. .............................. 18
INTERNSHIP REPORT BY TEMESEGEN ERMIAS Page vi

List of Abbreviations
EEPCO Ethiopia electric light and power corporation
HTSC Hawassa textile share company
WWPTs Wastewater treatment plants
AWWA American Water Works Association
CAD Computer added design
MCB Main circuit breaker
AC Alternating current
DC Direct current
NO Normally open
NC Normally close
INTERNSHIP REPORT BY TEMESEGEN ERMIAS Page vii

1. BACK GROUND OF HAWASSA TEXTILE SHARE

COMPANY
1.1 History of the company
Hawassa textile factory was established in November 1989. The textile mill is an integrated
modern factory located in the southern people regional administration capital city was 275km
south of Addis Ababa. It is designed to produces various kinds of woven fabrics from 100%
cotton as well as to finish polyester cotton blended and 100% polyester fabrics. The equipments
of factory are:-an automatic bale pluckier and high speed spinning machine, rapier looms a
modern air conditioning system organized laboratories west water treatment plant are among the
latest in the country and almost all are Italian origin.
The factors land holding is 371,000 square meter of which 31,275 is covered by building and
31,000by an effluent treatment lagoon. The total man power of the factory is 950. The work
force is relatively young with base knowledge to operate and maintain the installed machine and
equipment. The present monthly wage is birr 1.2 million.
Vision
To be export leader of the country by manufacturing 100% cotton products in order to satisfy
customers need.
Mission
To produce 100% pure cotton textile products this can satisfy customer need.
To expend the market share, there by generating profit.
To play vital role in the development of the country economy.
1.2 Main Service of the organization

Main production and market
A. Production capacity (annum)
The factory is designed to operate with the following product.
Installed physical capacity (annum)
100% cotton 11.1 million square meters
Poly% cotton 25.0 million square meters
INTERNSHIP REPORT BY TEMESEGEN ERMIAS Page 1

Attainable physical capacities (annum)
100% cotton 8.44 million square meters

Poly% cotton 6.172 million square meters
Some of products types 100% cotton grey bleached printed and dyed cretin.
100% cotton grey bleached printed and dyed poplin 1616-2424.
100% cotton grey bleached and dyed twill 2/1 32/216-3619 16*16.
1005 cotton grey bleached and printing sheeting 20*16-24*19-30*20and other contains.
100% cotton grey bleached and dyed will3/ 132/2*16-38*19-20*20-41*22.
Dyed PLC twill 65/35.
Dyed plain sols.
Quilt cover and pillow cases.
Bed sheet with pillow cases.
Flat and fit sheet etc.
At this time the company is not working at its full capacity and it is not producing most of the
above listed products.
B. Main customers and end users
The opportunity of cotton growth potential and increase in demand for cloth make of cotton in
foreign nations was making huge market demand in the past 20 years. Products for foreign
market were directly delivered by the factory. Its foreign customers in the past years were UK,
Belgium, Italy, Switzerland, Sweden and Germany. However, starting from last year all the
customers and end users are local. Off these
Addis Ababa foam
Kangaroo foam
Matias PLC
C. Export Market and Prospect
In the global market textile is the third largest market after tourism and the information industry.
As the textile demand increase with population and per capital consumption, growth and shifting
of the industry to the developing nations with cheap labor cost, Ethiopia textile has huge
potential for export. More over as the country enjoys access to European and American markets

exempted of duty tax and free from all quota restrictions, the textile and clothing industry in the
country has very good potential for export.
D. Opportunities
Cotton growth potential.
Increase in demand for cloth make of cotton in Europe and America.
Huge export market free of quota restriction and duty.
High domestic economic growth implying increase in disposable income.
Development of infrastructure facilities.
Political stability and liberation of economy.
E. Core Competence to Attract Partners
Majority of the machinerys reasonable new.
Has already developed export market and actively trying to develop others.
Better product quality and design.
Customer service.
Ideal location for expansion program.
Relatively skilled manpower and average age group.
F. Business Environment
General
Since 1993, the country has taken significant measures to revitalize the domestic economy and
create an environment conductive to the proper utilization of the countrys resources. The textile
sub-sector is one of the strategic sectors, which has being given due attention because of its back
and front linkage of its employment opportunity and its potential business environment both in
domestic and export market.
Social Environment
Ethiopia is one of the populous countries in the region and third in Africa with a population size
of 63 million. The annual growth rate is 2.9%.The high population size combined with the
growth of disposable income due to the economic development the country creates high potential
demand of clothing that has a wide gap between current production and demand. Above 50% of
the production is under the age of 20 that creates opportunity for reasonable cheap labor force
and at the same time high consumption of basic needs among which clothing is one.

Technological Environment
Even though the technology in textile is under continuous development to automation and
computer aided design (CAD) the textile industry is still grouped under the labor intensive
manufacturing. As the standard product or commodities of the industry still do not require highly
flexible equipments, the sector in Ethiopia can easily compete in both export and domestic
markets.
Economic Environment
In wide context, the world economy has being globalized and in order to participate in the
market, the country is making every preparation by due to the continuous reform measures taken.
The economy is growing at an average rate of 7.2% that contributes to growth in the disposable
income of the population. As all the micro economic indicators show this trend is expected to
continue in the coming years. A port from policy adjustments to improve the economy efforts
have being made in developing the infrastructure that is essential for creating new investment
opportunities.

Over all work Sections of the Company

Board of directors
General manager
Plan and Quality Commerce Finance Human and Production

information control department department administration and
department service dept technical
dept
Purchasing Sales
division division
General Personal Production and
Account administration technical dept
division
Cost and Man power Spinning

budget development division
division division
weaving
General division
service
Finishing
Clinic division
Knitting
Figure 1.1 Overall organization and structure of the company division

SPINNING WEAVING FINISHING GARMENT
Figure1. 2 Overall work sections of the company

There are different departments performing different and continuous tasks
These are;
Spinning department
Weaving department
Finishing department
Other utilize
Spinning work shop
The spinning department has two production lines for carded and combed yarn with capital of
24,288 spindles, which constitutes 9.4%of the installed national capacity. The installed
machineries include automatic bale pluckier, high speed cards, user auto leveler fitted drawing
formers lap formers, combers, roving frame, ring frames automatic winding machine electronic
assembly winding machine and two-for one twisters except cone winders. Assembly winders and
two-one twisters, which are made by savio, all the rest are manufactured by marzoli.
Weaving workshop
The weaving department consists of two warping machines, one sizing machine 124 somet (sm-
93) papir looms (15%of the installed national capacity of rapier loom), a brushing machine and
inspection machines.
Finishing work shop
The finishing department is capable of finishing 36 million square meter of 100%cotten and
polyester cotton blended fabrics per annum, which are woven in Hawassa and Arbaminch textile
factories. The scoring and bleaching process and the dyeing process use continuous system.
In addition mercerizing rotary screen-printing and shrink proofing are among some of facilities
available.

Other utilities
The factory is equipped with air conditioning water supply and treatment, steam generation,
diathermic oil heaters waste water treatment and physical and chemical quality control facilities.
Facilities
Electric power is supplied from the national grid of the Ethiopia electric light and Power
Corporation (EEPCO). The total installed capacity is 10,000KVA.
Water is supplied from its own deep well and from city water supply source.
Fuel fired boilers and diathermic oil are the source of steam and heating system.
Well-equipped mechanical and electrical work shop for maintenance service.
Communication services of telephone, telex, fax, p.o.box and email are available.
20 duplex staff canteen and a cafeteria with assembly hall.
Suppliers of main inputs and distance from the factory
Table 1.1Supplier of main inputs and distances from factory
s/n Raw material Name of suppliers Distance from the Remark

factory
1 Lint cotton Middle awash area 376km Local
2 Caustic soda Zeway caustic soda 90km/Europe Local/Europe
fact, Europe
3 Sulfuric acid Awash aluminum 257km Local
sulfate
4 Salt MWITE 275km Local
5 Dyestuff and chemical Different Europe Import
Ports and their distance from the factory

Table1. 2 Port and their distance from factory
s/n Name Distance

1 Bole air port 275km
2 Djibouti 1132km

1.3 Objectives of the Internship

General objective
The objective of this program is to expose us to the real job world and to assist us to
acquire problem solving practical skills and knowledge in the area of our study.
To give experimental knowledge under graduate students what real world work looks like
and aware those for their future career as well develop problem solving skill.
Specific objective
To improve practical skill of students,
To introduce students with the real working environment,
To develop ability of organizing and executing Electrical work,
To improve interpersonal communication skill,
To improve leadership skill,
To fill the gap between the theoretical knowledge and real (practical) work,
To understand about work ethics related issue, etc.
1.4 Scope of the Project

The main scope of this internship is to let the students to join different industries in order to
understand the practical application of different electrical courses which have been given to the
students for the past four years. And relate the theory with practical job in the real world.

2. PROJECT AND CONTRIBUTION

2.1 INTRODUCTION
Waste water treatment based on PLC
Wastewater treatment is an important function that affects all of us. It is vital to keep my living
environment hygienic and healthy, my water courses clean, and our manufacturing facilities
compliant with regulatory standards. Behind the scene, the wastewater treatment process
combines microbiology and chemistry with mechanical engineering, instrumentation and
automation techniques that offer high performance in a progressive way. Wastewater Treatment
Plant (WWTP) is a facility designed to receive the wastewater from primarily domestic,
commercial, and industrial sources and to remove materials that damage water quality and
threaten public health and safety when discharged into receiving streams or bodies of water. [1]
Waste treatment facilities face a number of trends that are having a broad impact on operations,
maintenance, and capital expenditures, including increasing labor, energy, and chemical costs.
Advanced process control is a tool that can help to minimize the impact of many of these trends.
Automation of wastewater plants, where facilities run unattended for some period of time, is an
essential element of a cost saving strategy. [6] At present, due to the increasing resource
constraints and the environmental requirements, textile industries units need to adopt a
sustainable approach and wastes need therefore to be viewed as unutilized resources. Ways and
means must be found to recover water and chemicals from these waste resources. Advanced
treatment methods, PLC based treatment with algae, appear to be promising because these
methods not only help in reducing the pollution but also provide a scope for recovery and
recycling of water and chemicals. The existing wastewater treatment in Hawassa textile factory
is they dont have any automatic control wastewater treatment and the cost expense for
chemicals to neutralize the wastewater is very costly. [3] This project seeks to give an overview
of the different advanced methods for treatment of textile industry effluents. The performance of
these advanced treatment methods as also their economic analysis, benefits and constraints have
been discussed in the project work. 2

The Algae Powered Wastewater Treatment Plant uses sunlight and algae to absorb waste and to
produce clean water. The application of algae cultivation, to capture and reuse nutrients found in
wastewater, can be applied to textile water treatment plant. [14]
Statement of Problem
Hawassa textile factory do not have automatic waste water treatment process and these
initiate my to design waste water treatment based on Semitic (PLCs7-300).
The existing waste water treatment in Hawassa textile factory is based on chemical
treatment ; as a result its running cost is so high .Hence I decided to design the waste
water treatment based biological based treatment .In addition reducing cost is powerful in
providing treated waste water and clean surrounding environment.
2.2 Objective
2.2.1 General objective
Waste water treatment based on PLC.
2.2.2 Specific objective
To reduce human power.
To give a clear understanding of the basic concept of waste water composition treatment
in the tank, pollutants in waste water, effluent characteristics and its control mechanism
using PLCs7-300.
To protect environmental pollution that by waste water.
To minimize the running cost of the company.
Significance of the project
The design of PLC based on waste water treatment plant controlling system has enormous
advantages for the Hawassa textile share company. This project has great advantage to the
company. Using PLC based automatic controller enables to have reliable system
performance.
2.3 Feasibility
Industry has wide number of sub-sectors, from the production of raw material to finished
product, and water management is part of whole environmental policy of emission
minimization. This project is not there in Hawassa textile share company but I design project

based on biological treatment .The project is not functioned as a result its running cost is so
high .
The existing waste water is based on chemical treatment mechanism and its control system is
manually not automatic.
Controller
Simple closed loop control system:
Controller Actuator Process Output Output
Sensor
Figure2. 3 Simple closed loop controls

Overall control system performance depends on the proper choice of each component of a
control loop. Advanced control strategies are found in WWTPs.
Programmable Logic Controller (PLC S7-300)
The S7-300 is the most often sold SIMATIC controller which makes successful automation
solutions possible. The S7-300 for system solutions with its main importance in production
engineering provides an automation plat form which means best solution for your applications.
Permanent innovation makes this automation plat form continuously more valuable. It is
characterized by:
Timers in Siemens S7-300
Siemens S7-300 PLC can be programmed with five types of timers:
S_PULSE Pulse S5 Timer
S_PEXT Extended Pulse S5 Timer
S_ODT On-Delay S5 Timer
S_ODTS Retentive On-Delay S5 Timer
S_OFFDT Off-Delay S5 Timer
Compact design

Many functions are integrated into the CPU (I/O, Technology functions,
PROFIBUS/PROFINET connection)
Maintenance-free thanks to data retentively on Micro Memory Card
Bits 0 through 9 of the timer word contain the time value in binary code. The time value
specifies a number of units. The time updating decrements the time value by one unit at an
interval designated by the time base; Decrementing continues until the time value is equal to
zero. The time range is from 0 to 9,990 seconds. The maximum time value that you can enter is
9,990 seconds, or 2H_46M_30S. These times differ in function but all of them have the block
shown in Figure below in common.
Timer number
Timer type
S Q
TV BI
R BCD
Figure2.4 Timer block diagram

Where,
S: is the Set (Trigger) signal of the timer.
TV: is the time value stored in the timer which must be in the form (S5T#tv). The
maximum time value for tv that you can enter is 9,990 seconds, or 2H_46M_30S.
R: is the Reset signal of the timer.
Q: is the output of the timer.
BI: is the current time in binary code.
BCD: is the current time in binary coded decimal code.
Timer number: this can be in the form (T#), where # can be any number in the range (0-
255), since Siemens S7-300 PLC allows the use of 256 timers at max.
Timer type: is one of the 5 timer types mentioned above.
A Programmable Logic Controller, PLC or Programmable Controller is a digital computer used
for automation of electromechanical processes. Unlike general-purpose computers, the PLC is
designed for multiple inputs and output arrangements, extended temperature ranges, immunity to

electrical noise, and resistance to vibration and impact. Programs to control machine operation
are typically stored in battery-backed-up or non-volatile memory. My Proposed system can be
divided into three main modules- sensing, decision making and implementation. In my project
Siemens S7-300 is used. The S7-300 enables space-saving and modular configurations. In a
single-tiered configuration, S7-300 can support 256 I/O, and in multi-tiered configurations up to
1024 I/O. single S7-300 if deployed in an industry can automate and monitor a large number of
tanks. PLC S7-300 components Basically PLC consists of the following elements:
Power supply
Central Processing unit (CPU)
Programming devices
Input and output module
Figure2. 5 Siemen PL S7-300

Figure2.6 Basic components of PLC

In wastewater applications, a Master Logic PLC can be installed on treatment units and
networked with computer. Honeywells ML server interface software allows the Experian HS
supervisory software to have direct access to all memory locations in the Master Logic PLC for
use in operator displays, trends, reports, etc.
Manual switching
Sensor input PLC Output
Figure2. 7 General block diagram of the controller and input output interface
The proposed system will control and monitor the liquid level of the tank, temperature of the
wastewater, flow rate, pressure, odor, PH value, color, conductivity and other parameters
continuously and will ensure that a sufficient level of water is maintained. It can be used to
prevent industrial accident by overfilling of any open container, to prevent overfilling of any

closed container thereby creating overpressure condition. The high number of the input output
port of the PLC will enable this single system to control large number of tanks single handedly.
Alarm Systems
Alarm systems should be provided for pump stations. The alarm should be activated in cases of
power failure, sump pump failure, pump failure, unauthorized entry, or any cause of pump
station malfunction, minimum level and maximum level of wastewater, open or close failure in
the valves. Pumping station alarms should be telemetered to a textile facility that is manned 24
hours a day. If such a facility is not available and a 24-hour holding capacity is not provided, the
alarm should be telemetered to central control room during normal working hours and
responsible person(s) in charge of the lift station during to the home of the off-duty hours.
2.4 Methodology
In every industry there is wastewater treatment. But the difference is on running cost and the
effectiveness of the work. Hawassa also it has wastewater treatment mechanism but it has some
problems; as I observed in the internship program. First I asked the current problem with it to the
manager. After I gained some information I went to the place or section in which the waste water
treatment is found. Then I observed all over the flow process of the waste water and I understand
where it comes from. From my observation the main problem is in the control system and the
type of treatment mechanism. Then finally I have selected the PLC S7-300 control system and
Algae based treatment. But in order to fulfill all these things I have used some materials
Sensor input
Liquid level sensor
PH sensor (output also PH meter)
Oxygen sensor (output also oxygen)
Valves
Water inlet valve purge valve
Controller
PLC S7-300 module/software

The overall waste water treatment process:-
Screen Heat Waiting Fine Biologica

filter recovery tank screen l tank
systeeeee
e
Sludge tank Thickening tank Sedimentation

tank
Environment
Figure2. 8 General process block diagram of waste water treatment

Some description of the above block diagram:-
Biological tank: it is used to adjust the amount of biological oxidation of the waste water.
Sedimentation tank:- the waste water coming from biological oxidation step is pumped to
the sedimentation tank ,where the separation the liquid part from the sludge takes place
by the means of over flow system.
Sludge pump:-it is installed in the sedimentation tank, it works by the minimum level
sensor in the sedimentation tank constant and it is controlled by the means of two
pave/work timers its control switch is automatic manual
2.5 Literature Review

2.5.1 Background
This literature review on wastes from water treatment plants discusses previous literature reviews
on the subject, sources and types of waste, characteristics of each type of waste, and waste
management. The discussion of management of sludge (waste) covers minimizing sludge
production, methods of sludge treatment, and an ultimate sludge disposal. In advanced countries,
the coagulationflocculation is most widely used method in textile wastewater treatment plants.
[15] It can be used either as a pre-treatment, post-treatment, or even as a main treatment system
(Ghr et al., 1994; Marmagne and Coste, 1996). This method can efficiently remove mainly
sulphur and disperse dyes, whereas acid, direct, reactive and vat dyes presented very low
coagulationflocculation capacity (Marmagne and Coste, 1996; Vandevivere et al., 1998).

Filtration methods such as ultra-filtration, nano filtration and reverse osmosis have been used for
water reuse and chemical recovery. [4] In the textile industry, these filtration methods can be
used for both filtering and recycling. It is not only pigment-rich streams but also mercerizing and
bleaching wastewaters. The specific temperature and chemical composition of the wastewater
determine the type and porosity of the filter to be applied (Porter, 1997). [5] The main drawbacks
of membrane technology are the high investment costs, the potential membrane fouling,
produces secondary waste streams which need further treatment (Robinson et al., 2001). A very
good option would be to consider an anaerobic pre-treatment followed by aerobic and membrane
post-treatments in order to recycle the water. [8]
2.5.2 Previous Reports
Duringtheperiod1969 to 1981 the American Water Works Association (AWWA) Research
Foundation and the AWWA Sludge Disposal Committee prepared a series of reports with a
comprehensive literature review on the nature and Solutions .The first report, prepared by the
AWWA Research Foundation, was divided in to four Parts (AWW A Research Foundation,
1969a, 1969b, 1969c, 1970) and was entitled "Disposal of Wastes from Water Treatment Plants.
6 [13] "The first part of this report (AWWA, 1969a) covered the status of research and
engineering practices for treating various wastes from water treatment plants. The second part
(AWWA, 1969b) reviewed plant operations for the disposal of various types of wastes, and the
regulatory aspects of disposal. The third part (AWWA, 1969c) described various treatment
processes employed and their efficiency and degree of success, and presented cost analyses. The
last part (AWWA, 1970) summarized research needs, engineering needs, plant operation needs,
and regulatory needs. [9]
2.5.3 Sources and Types of Waste
A water treatment plant not only produces drinking water but is also a Solids generator. The
residues (solids or wastes) come principally from clarifier basins and filter back washes. These
residues contain solids which are derived from suspended and dissolved solids in the raw water,
the addition of chemicals, and chemical reactions.[7] Depending on the treatment process
employed, wastes from water treatment plants can be classified as alum, iron, or polymer sludge
from coagulation and sedimentation; lime sludge and brine wastes from softening. [10]

2.5.4 Waste water characteristics

The amount and composition of waste produced through each treatment Process are
unpredictable. Because of the wide variation in raw water quality and treatment operations,
sledges are different in their characteristics and quantities from time to time with in the same
treatment plant, and from plant to plant. [11] Russelmann (1968) discussed general
characteristics of water plant wastes. In addition, he addressed special characteristics of
coagulation wastes, filter back washes, ion-exchange brines, and screenings from a few water
suppliers. He concluded that it is impossible to make generalizations concerning sludge
production in terms of millions of gallons of water treated because sludge production is entirely
dependent on raw water quality, the method of treatment, and efficiencies of the treatment
processes. [12]
Textile industry includes a wide number of sub-sectors, from the production of raw material to
the finished product, and water management is part of the whole environmental policy for
emission minimization. Other issues being air and solid management with the aim of their 7
minimization and or reuse the output parameters responsible for degradation of the environment
include solids and hazardous wastes, sludge, low grade large measure of heat, wastewater
discharges and contaminated atmospheric air and flue gases. [2] This project is there in Hawassa,
but not functions well, and it is manually control and chemical based treatment, as a result its
running cost is so high.
2.6 The existing wastewater treatment with comparison the modified wastewater
treatment
The existing waste water treatment is based on the chemical treatment mechanism and its control
system is manually not automatic. So, as a result the chemical based wastewater
Treatment is very costly.
Table2. 3 Comparison of the existing with modified waste water treatment.
The existing wastewater treatment The modified waste water treatment

Chemical based on waste water treatment PLC based waste water treatment
It has no heat recovery machine It has heat recovery machine
Manually controlling system Automatic or PLC based control system
It has no waiting tanker It has waiting tanker

The modified wastewater treatment would design based on the algae (biological) treatment. In
this project as explained in the above table, the great modification is based on the biological
(algae) treatment and its controller is PLC s7-300.

3. INTERNSHIP EXPERIENCE
3.1 Getting and Visiting the Company
Before I admitted in to Hawassa Textile factory I have been told by students of
Electromechanical engineering as they were overviewed by the school of Electromechanical that
attached students shall be abided by principles and procedures of the hosting. During the
entrance time the companies training center officers also advised us how I manage our time and
use it effectively. Furthermore, they show us overview of company as well as ethics of
companies.
3.2 Working Sections

Overall System Components and Operations of the Company
Hawassa textile Share Company is integrated company which processes 100% of cotton from
spinning up to finishing in their respective section and also garment processing will be done by
some machine followed by kittening. The main work flow is spinning section, weaving section
and substation department.
Spinning Department
Spinning is the first step in the textile industry after ginning. It is the process of changing lint
fiber to the weave able or knittable yarn. Spinning department includes all the activities required
to convert cotton in to yarn. The major raw material for spinning is cotton and polyester.
Contribution of spinning operations makes to the overhead of the company at the planned cost of
low materials consumable & personnel. There are two types of yarn are produced those are long
fiber and short fiber yarn those has different quality which means the one which have long fiber
has high quality & the one which have short fiber has low quality.
The department contains machines like Mixing Bale Plucker, Metal detector, Six-step cleaner,
Two-Pitter, Auto-Mixer, Horizontal Opener, Carding, Drawing (primary and secondary passage),
Roving, Ring frame, Open-end, Winding, Twister and Doubler.
This Spinning department has five sections and two production lines.
1. The five sections are:
Blower room
Open end
Roving frame

Ring frame
Yarn store
2. The two production lines are:
Open end line
Ring frame line
The spinning department process of flow line order are described in Figure below
Bale
pluckier
Opener Carding
Metal Six step Mixer
detector cleaner
Winding Drawing frame

Ring frame Roving
frame 1st & 2ndstage
Open-end
Yarn
machine
store
Figure3. 9 Process of spinning section

Sections in spinning department
1. Blow room
Blow room is the first process of spinning department where cotton balls/fiber balls are process
for blending, opening and cleaning and to form a required sheet of fibers for subsequent process
of carding. It contains Bale Pucker, Metal detector, Six-step beater, Two-pitter, Auto-Mixer and
Horizontal opener.
Basic operation involved in the blow room
Opening: - opening is the first operation in the blow room carried out to the stage of flocks
In the blow room and to the stage of individual fiber in the cards
Cleaning: -this is removal of impurities to make the cotton as clean as possible
Dust removal: - to remove dusts which are completely enclosed in the flocks.
Mixing or blending: - to achieve the required quality of yarn by blending different kinds
of cotton in to particular ratio.
Even feed of the material: -to produce a lap of uniform weight per unit length or to
Process the maximum quality which is suitable for carding.
Figure3. 10 Bale plucker

2. Carding Machine
Carding operation is done after blow rom process. Blow room product is lap or chute, after
carding the output is sliver. Carded sliver feeds to drawing frame for making leveled sliver. This
process is the most important part of spinning. For this reason carding is called the heart of
spinning mill and well carding is half spun. Carding is done for both carded and combed yarns.
The following are functions of carding: -
Carding is done for the individualization of the fibers
Sliver formation also made by carding machine
Elimination of dust
To facilitate the next drawing frame action
Disentangling of naps
Elimination of short fibers
Fiber parallelization
Sliver formation
Remaining impurities and dust are eliminated

Figure3.11 Carding machine
3. Drawing Frame Machine

Drawing frame is third process of spinning department the card sliver has hooked fiber &
entangled fiber those to be paralyzed regularized the strand/sliver (blend, mixing of cotton &
polyester in some ratio) the cotton is to give conformability for wearing & the polyester is to
give high strength The ratio is designed as per desire of the customer & from that the drawn
sliver lead to the open end process or ring line.
There are two types of drawing frame machine in the factory those are
First drawing frame machine
Second drawing frame machine.
First drawing frame machine is used for doubling (i.e. eight input with one output), elongation
and mixing (cotton with polyester).
Second drawing frame machine is in addition to doing the function of first drawing machine it
has special advantage which is leveling the sliver weight. Equipped with electronic auto leveling
system.
Auto-leveler is an additional device which is meant for correcting the linear density variations
in the delivered sliver by changing either the main draft or break draft of the drafting system,
according to the feed variation.

Figure3.12 Drawing machine

4. Roving Frame
Roving is fifth process in carded yarn production & seventh process in camped yarn production
of the spinning department sliver is feed to roving machine &passed through creel & drafting
zones.
There are two basic reasons for using roving frame:-
1. The roving sliver is thick and untwisted. Because of its hairiness and fly is created. So
draft is needed to reduce the linear density of sliver. The ring drafting arrangement has no
capable of changing the roving slivers in to yarn.
2. Drawing frame can represent the worst concern able mode of transport and representation
of feed materials to ring spinning frame.
Figure3.13 Roving frame

5. Ring Frame
Ring frame which is the process in carded yarn production eighth process in combed yarn production
roving bobbins are reeled over hangers & roving is passed through guide bars, drafting to draft for
required yarn count & through ring & ring traveler for the formation of yarn which is wound on cops
fitted over roving spindles.
It has unique advantage over spinning technology:
It is universally applied in most of the textile fiber can be spun to required fineness.
The yarn spun from this machine demonstrates excellent quality feature uniform structure
and good strength.
It is easy to operate as compared to other spinning machines
Disadvantages:
More process stage, roving stage exist as extra process compare the other system
The high speed of the traveler damages the fibers capacity of the crop is limited
Energy cost is very high
Low production rate
Objectives of ring frame are to:
Drafting the roving until the required fineness is achieved
Winding the twisted strand (yarn) in a form suitable for storage, transportation and
further processing.
Figure3.14 Ring frame

6. Winding
Winding which seventh process in carded yarn production & ninth process is in combed yarn
production ring laps are passed through User yarn cleaner & upgrade the yarn marketing or
weaving purpose (for next process).
Figure3. 15 Winding machine

7. Twisting and Doubling
This machine have the same working principle but Twisting use for twisting the yarn in order to get
high strength, and doubling guise fore doubling the yarn.
Figure3. 16 Twisting and doubler machine

8. Open Ending Machine

Open end Machine is a device which is used to drafting fiber masses in to individual fiber. It is
also used for transporting and depositing the fibers to yarn end. It is a means of winding the yarn
in to a package of cone. The open ending machine which described above is shown in the Figure
below.
Figure3.17 Open ending machine
9. Yarn Store
This section is the final section of spinning department and use to store the yarn produces by the
production lines.
Figure3.18 Yarn store

Weaving Department
Weaving is the interlacing of two sets of yarns, i.e. warp and weft yarns at right angle to each
other. In HTSC weaving section includes warping up to inspection machines. The flow chart
described in the Figure below.
Warping Sizing Looming Inspection

Brushing
Figure3.19 Process flow of weaving section
Warping process
This is the process of changing the winding yarn from small size of individual cones to the
bigger cylindrical size roller. This makes suitable for looming and sizing up purpose.
Objectives of warp winding processes are:-
Formation of suitable package for warping
Checking and clearing the yarn from spinning defects
1. Sizing process
It is the process of improving the strength of the yarn by passing through hot solution of starch.
This provides suitable for looming machine.
Objectives of sizing processes are:
To increase the smoothness of warp yarn by gluing the protrude fibers to the core by
means of size;
To apply a protective coating to the yarn to enable it so as to with stand complex stress
in weaving machines mean while maintaining or enhancing its strength and elasticity;
To improve the weave ability of warp by reducing warp breakages;
2. Looming process
After the required number of warp yarns in the fabrics wound onto the weavers beam, the warp
beam ends are then passed through the drop wires, the heddles of the harness frames and the dent
of the reed. This achieved by drawing in and/or tying in (the choice depending up on whether or
not the new warp is different and from the warp already on the loom).

3. Fabric inspection and rejection

The inspection process might start with 100% inspection; check of every items or random sample
based on statistical calculations as a norm one would expect 100% examination for the first
customer order and there after random sampling based on the quantities to be produced.
Machine Description of Weaving Section
A. Warping Machine
Warping machines have a very simple design, which results in higher speed & consequently in
output increase. This machine is shown in the Figure below.
Figure3. 20 Warping machine

In warping, the yarns are withdrawn from the single-end yarn packages on the creel & directly
wound on a beam. Warping is used to make smaller intermediate beams called wrappers beams.
These smaller beams are combined later at the sizing stage to produce the weavers beam.
B. Textile Sizing Machine
Sizing machine uses chemical for reducing the chances of breaking due to the friction in the
weaving process. The sizing machine improved the process by sizing a warp before putting it.

C. Brushing Machine
Figure3. 21 Sizing machine

The purpose of this machine is to remove the waste of the cloth and to change the weaving clothe
roller to bunch.
D. Inspection Machine
These machines are designed so that rolls of fabric can be mounted behind the inspection table
under adequate light and wound as the fabric leave the table. These machines are either power
driven or the checker pulls the fabric over the inspection table.
Power Flow Section (Substation in Hawassa Textile S.C)
Hawassa textile share company power section is responsible for supplying continues power
supply to each machines and equipment in all departments especially for the production
department. The power delivered to each machine and equipment should be the necessary value
in order to function properly consequently the machine and equipment can function without
getting failure repeatedly, a few order or less power inputs may cause a series draw back since
the machine and equipment are pretty sensitive except power taken by the PLCs and power used
to initiate the contactors which is 24v dc each motor uses a three phase 380vac.
AC Mains
The power directly given from Hawassa city substation to the factory is 10,000 KVA. This
amount of power is distributed to six medium voltages through a ring system (a system in which
two lines come out from the supply distributer, though, when one of the line face fault the other
line is used as supply. The 15kv power from the medium voltage control board passes through

step dawn transformers which convert the 15kv to 0.4kv or 380v. This is given to the low voltage
control board. Within the medium voltage control board there are different types of switch like
motorized and earthling and it has also fuse disconnections which are responsible for protect
overload.
The medium voltage control board used for two purposes:
as switch during maintenance
as a protection (automatically) during fault
From the low voltage control boards the motors and electrical outlets of different department are
connected.
Power Factor Correction
The ratio of real power to apparent power is called power factor. Inductive loads cause current to
lag behind voltage while capacitive loads causes current to lead voltage. Also the presence of
harmonics current decreases the power factor. The power factor uses the total rms, this including
all harmonics. .
Active power (watt):-is that portion of electrical power that is real, it includes heat loss utility
charge are based on watts.
Apparent power (VA):-is the product of rms voltage and current which relates to the effective
load seen by transformer and current conductors.
Reactive power (VAR):-is the reactive component of the apparent power causes by a phase shift
between a current and voltage in inductors (coils) and capacitors. VARS are present in a
distribution system.
To avoid unnecessary losses, or to meet the acceptable load requirements of the energy supply
utility, power factor correction is often required with induction motors, particularly for large
machines or in installations running many machines.
The most common power factor correction is by means of added capacitors however, under
certain circumstances the motor controller can also be used for this purpose. In Hawassa textile
S.C there is a capacitor bank with a four stage power factor correction capability in which each
stage provide increased power factor correction capability.

Protection and Control Devices

When motors are used, there should be the right controlling system as well as protective devices.
The power flow can be seen below.
3- supply

Bus bar

Fuse

Contactor

Overload relay / Thermal switch

Motor/ Load
All these are connected in series and have their own rating for different KW motors. Electric
circuit should have the following main parts. These are;
Source of energy The control device
The conductor The load
List of protective device

1. Electrical Circuit Breakers
A circuit breaker is a protective device that interrupts current flow in a fault condition. It is not
intended for routine use to turn the load on and off. It also a device designed to open and close a
circuit by non-automatic means, and to open the circuit automatically on a predetermined over
current without damage to itself when properly applied within its rating.
Operation
In order to allow power to pass through the breaker, the operating lever is placed in the ON
position. This mechanically closes the contact in the breaker. When current pass through the
device; a magnetic field is developed in the bar. The intensity of this fields focuses through a
large piece of metal at the end of movable arm. When the current existed as predetermined
amount, the magnetic field will pull to the right, releasing the lever and the trip mechanism,

allowing the spring to pull contact open. This will disconnect power to the control circuit. To
reset the breaker, it must first be placed in the OFF position and return to the ON position.
Function
Circuit breakers as switch: - A breaker is a control device, or a controller. A circuit breaker can
control and protect an electrical circuit and people operating the utilization equipment. Circuit
breakers are not designed as replacements for operating controls such as relays, contactors, or
motor starters.
As current levels to be broken:-In current quantity breaker must be able to open overload level
currents.
As over current protection:-Any current in excess of the rated current of the equipment or the
capacity of a conductor. Circuit breakers provide a level of safety against over current
conditions in electrical circuits.
Short Circuits:-A short circuit is an unintended path through which current can flow. Any time
current flows in a path that is not the normal path, we say that the circuit is shorted. A circuit
breaker must be able to respond to a short circuit, which can present a large current flow in a
short period of time.
Generally circuit breakers have the following main advantages:
Sense the current flowing in the circuit
Measure the current flowing in the circuit
Compare the measured current level to its pre-set trip point
Act within a predetermined time period by opening the circuit as quickly as possible to
Limit the amount of energy that is allowed to flow after the trip point has been reached.
2. Contactors
A contactor is an electrically controlled switch used for switching a power circuit, similar to a
relay except with higher current ratings. A contactor is controlled by a circuit which has a much
lower power level than the switched circuit. Contactors come in many forms with varying
capacities and features Contactors are used to control electric motors, lighting, heating, capacitor
banks, thermal evaporators, and other electrical loads. Contactor does not provide overload
protection. When the coil is energized, the moveable contacts are closed against the stationary
contacts. Figure shows parts of contactor.

Figure3. 22 Contactor parts
Operating principle of contactor

Contactors are designed to be directly connected to high-current load devices. Devices switching
more than 15 amperes or in circuits rated more than a few kilowatts are usually called contactors.
Apart from optional auxiliary low current contacts, contactors are almost exclusively fitted with
normally open contacts. Unlike relays, contactors are designed with features to control and
suppress the arc produced when interrupting heavy motor currents. When current passes through
the electromagnet, a magnetic field is produced; this attracts the moving core of the contactor.
The electromagnet coil draws more current initially, until its inductance increases when the metal
core enters the coil. The moving contact is propelled by the moving core; the force developed by
the electromagnet holds the moving and fixed contacts together. When the contactor coil is de-
energized, gravity or a spring returns the electromagnet core to its initial position and opens the
contacts.
3. Relays
Relays control current flow in a circuit based on signals obtained from an information source.
An electric signal (Voltage) gets sent to the coil creating a magnetic field, closing the armature,
which closes Normally Open (N.O.) and opens Normally Closed (N.C.) Contacts.
Relays tend to be of lower capacity and are usually designed for both normally closed and
normally open applications.
Operation principle of a Relay
It consists of an operating coil wound around an electromagnet pole piece, a moving armature
and one or more sets of contacts. When a voltage of the correct value is applied across the coil
terminals, the resulting current flow through the coil produces a magnetic field similar to a bar
magnet. The armature is attracted by the magnetic field and so moves a small distance. This
movement operates the contact.
4. Electrical Fuses
In electronics fuse is a type of low resistance resistor that acts as a sacrificial device to provide
over current protection, of either the load or source circuit. It is Over current protection devices
are essential in electrical systems to limit threats to human life and property damage. Figure 2.9
shows a typical fuse parts.
Figure3. 23 Fuse parts

Characteristic parameters of fuses are:-Speed, Breaking capacity and Voltage drop.
Switch: - a switch is a device for making, breaking or changing the connections in an electric
circuit.
Push button: - is a device that provides control of equipment by pressing a button so that it
makes or breaks an electric circuit. When push button is pressed by applying force, the path of
electric current opens or breaks.
Indicator Lamps: - The colors are usually red, green, but other colors are also available. Red
lamps are reserved for safety critical indicators (power is on, the machine is running, an access
panel is open, or that a fault has occurred). Green usually indicates safe conditions (power to the
motor is off, brakes are on, etc.).
Limit switch: - is like a 1 NO +1 NC push buttons. The push button is actuated by hand whereas
the limit switch operated mechanically. The main function of the limit switch is to open or closed
an electric circuit when physical limit of the operation of the controlled device has reached. for
instance, a printing machine stop automatically when paper is fed in a wrong way as the limit
switch installed on its automatically pressed with the pressure of the paper.
In roving frame machine it is used to balance the bobble position move ups and down.

Controlling of three phase motors

The controlling system for three phase motors is most of the time in star or delta. However,
sometimes both connections star and delta are used to control a motor at a time. A motor ready
for work can be checked whether right to work or not by using the following methods using
digital multi meter.
Phase to ground should read nothing or should read in Mega ohm.
Phase to phase reading between the three phases should be equal.
Starting and ending terminals of the conductor in the winding should be continuous
In the industry, motor problem is the following is the main point is show below.
Loose connection
Over loading
Over heating
Insulation defect
To avoid this problem we have used different mechanisms.
These mechanisms are:-
Main power checked
Controlling power checked
Fuse checked
Checked motor starting star or delta
Inverters
An inverter is a motor control element that adjusts the speed of an AC induction motor. It does
this by varying the frequency of the AC power to the motor. An inverter also adjusts the voltage
to the motor.
In HTSC inverter is used to control the speed of motors in drawing frame machine. The
controlling is done by using frequency variation of the supplied voltage. For simplicity
potentiometer is used for adjustment of the frequency.
Operation principle of inverter
Most inverters are of the variable voltage, variable frequency design. The converter section uses
semiconductor devices to rectify (convert) the incoming fixed voltage, fixed frequency 3-phase
AC power to DC voltage which is stored in the bus capacitor bank. Then it becomes a steady
source of current for the power devices which are located in what is known as the inverting

section. The inverting section absorbs power from the DC bus capacitor bank, inverts it back to
simulated 3-Phase AC sine waves of varying voltage and varying frequency that are typically
used to vary the speed of a 3-phase induction motor.
Rectifier (converter)
A rectifier is an electrical device that converts alternating current (AC), which periodically
reverses direction, to direct current (DC), which flows in only one direction. Rectifiers are used
in various devices, including:-DC power supplies, a source of power instead of generating
current and High-voltage direct current power transmission systems.
HTSC use converter at warping machine for controlling the speed of the DC motor.
Potentiometer is used for adjustment the armature voltage which is the main parameter in
controlling speed of DC motor.
Steam boiler
Steam boiler or simply a boiler is basically a closed vessel into which water is heated until the
water is converted into steam at required pressure. This is most basic definition of boiler.
Working Principle of Boiler
The basic working principle of boiler is very simple and easy to understand. The boiler is
essentially a closed vessel inside which water is stored. Fuel in our case wood or coffee husk
briquettes is bunt in a furnace and hot gasses are produced. These hot gasses come in contact
with water vessel where the heat of these hot gases transfer to the water and consequently steam
is produced in the boiler. Then this steam is piped to the turbine of thermal power plant. There
are many different types of boiler utilized for different purposes like running a production unit,
sanitizing some area, sterilizing equipment, to warm up the surroundings etc.
The boiler in the HTSC uses wood or coffee husk briquettes as a fuel and it generate up to 10.33
bar steam and evaporation rate 1500 kg/hr. The steam generated is supplied to the sizing or
weaving preparatory room.

Figure3. 24 Steam boiler in HTSC

Basic boiler controls
Boilers have to provide steam or hot water whenever heat is needed. A conventional boiler
management control system is often set to provide a continuous hot water or steam supply.
Boilers can be left enabled at no-load conditions, during which time the water temperature will
be held at the designed temperature. Frequent warm-up and shut-down of boilers causes stress
buildup. Boiler manufacturers recommendations provide specific guidelines in this area of
operation. Unless a low-limit for water temperature is used, hot water boiler burners are not
controlled to provide water temperatures based on outdoor temperatures, because the reset
schedules require water temperatures to be supplied below the dew point temperature of the
furnace. Some boilers require incoming water temperatures to be above 140F before going to
high-fire.
The following are three ways to control the output of a commercial boiler:
1. ON/OFF (cycling) control
2. High-fire/low-fire control
3. Modulating control
On/off (cycling) control is most common for small boilers. The burner cycles on and off to
maintain steam pressure or water temperature. Cycling control causes losses in efficiency
because of the cooling (which is necessary for safety) of the fireside surfaces by the natural draft
from the stack during the off, pre-purge and post-purge cycles. This type of controlling is used in
HTSC.

Types of sensors used for controlling the operation of the HTSC steam boiler are:-
Water level sensor
Pressure senor
Temperature sensor
A. Water level sensor:-this level sensor is used to measure the level water in the boiler. If the
level is below minimum allowed water level it will send signal for the alarm and for FD
Fan (water feeding motor) and if the water level reaches the required level this sensor send
signal for FD Fan to stop feeding water.
B. Pressure sensor: - the pressure sensor is used to control the pressure level of the steam.
The maximum allowed pressure is up to 8 bar sine the company is not working at its full
capacity it is sated at 5 bar at this time.
C. Temperature sensor: - the temperature sensor used for controlling the level of
temperature in furnace.
3.3 Tasks Performed During the Internship Period

During this third month internship period with the support of our mentors and their assignment
and supervision we were doing different tasks among them some are on board connecting and
testing different motor controlling circuits:
Direct on-line starting method
Forward reverse method
Star delta starting method
Sequential starting method
Dynamic break method
1. Direct on-line Motor Starting Method
The simplest form of motor starting for the induction motor is the direct online starter consist
MCB or circuit breaker, contactor, and an over load relay for protection. Electromagnetic
contactor which can be opened by the thermal overload relay under fault condition. In this motor
starting mode we made the connection.
Different equipments needed for the direct on line starting method:-
Three phase induction motor
One overload relay

One contactor
the star and stop push buttons
Cable
The procedures that we followed when we constructing the circuit were: first we recognized both
the normal open and normally closed self-hold (auxiliary) of the contactor by measuring their
continuity with a multi meter. Then we checked the fuses and overload relay continuity lastly we
constructed the following circuit as follows:
Figure3. 25 Direct on-line starting method

As I see the purpose of this connection mode is run the motor only one direction. So in this
motor starting mode there exists high starting current and high starting torque. In HTSC this type
of starting mechanisms used in roving machine.
2. Forward reverse motor Starting method
In this kind of motor starting we made the circuit by following same procedure from the above
motor starting mode using the desired materials such as three phase induction motor, two
contactors i.e. one forward mode and one for reverse mode, one overload relay, two start and
stop push buttons, four fuses and cables. Here as we understand the purpose of this motor is to
run the given three phase induction motor either in forward or reverse direction manually by
pressing the start and stop push buttons in both cases such that first the motor run in forward
mode after we pressed the forward push button and then we press the stop push button and after a
few minute we press the reverse start push button and will run in reverse mode.
In HTSC, bell plucker and open-end machines are used this type of starting.

Figure3. 26 Forward reverse
3. Star-Delta Motor Starting

In this motor starting mode I constructed the circuit following similar procedures from the above
motor starting modes using the materials such as, three phase induction motor, four fuses, three
contactors i.e. one main contractor, one star contactor and one delta contactor , one overload
relay, stop and start push buttons, timer, signal induction lamps and cables . Here I constructed
the circuit as in shown in the following figures with two contactors i.e. both the star and delta
contactors depend on the main contactor thus when the power is on the main contactors and the
star contactor will be energized and the motor will run in star mode and after a few minute
counted on the timer, the timer make.
The star self-hold normally open and make the delta self-hold normally closed so that the delta
contactor will be energized and the motor run in delta mode. This will reduce high starting
current and torque.
In HTSC, drawing frame machine used this type of starting mechanisms.

Figure3. 27 Control diagram of star delta starter
Figure3. 28 Power diagram of star delta starting
4. Dynamic break (motor auto-stopping method)

Dynamic braking: Lowers the wear of friction-based braking components, and additionally
regeneration can also lower energy consumption.
Principle of operation:-When braking, the motor fields are connected across either the main the
motor armatures are connected across either the brake grids or supply line. When the stop signal

is applied the DC current from rectifier will create a stationary flux across the rotor this will stop
the motor from rotating.
Figure3. 29 Dynamic break

5. Sequential motor starting method
In industrial processing operation there are cases where machineries should be started one after
another.
Manually
Sequential starting of motors means starting the motors one after the other. This type of control
necessary where second machine before starting must have all the auxiliary equipment. We made
the circuit by following same procedure using the desired materials such as three contactors,
three overload relay, three start and one stop push buttons, and cables.
Operation: the first motor can be started by pressing push button 1hold on contact 1 will close
and the supply to relay will commence through 1even if switch 1 is released. The second relay
gets supply through contact 1 and third relay get supply through second contact, the third motor
can be started only when 2nd motor is running. The second motor can be started only when first
motor running. The third motor can be stopped by pressing switch 3. When second motor is
stopped the third motor will stop automatically. When first motor is stopped by pressing switch1
all the three motor will stop.

Figure3. 30 Control and power circuit of 3 stages sequential control.
3.4 Procedures used to perform different tasks

To execute something first it is better to know about the system you are going to perform. This
makes you confident to work and meet your target. While we perform our task for the first time
we have worked with skilled operator and, chief electrician and additionally to strength

the knowledge about certain subject we read manuals which concern about it. We always ask
questions which are not clear for us and ask the experienced person to show us which we want to
know. Especially working with skillful operators has a great advantage to get more information
have performed whole internship work task with all workers in passion and friendly.
Personally I think friendship make all things right and help someone to achieve his goal. In short
I have used the following procedures:
Asking people who know
Reading manuals

4. THE OVERALL BENEFIT THAT GAINED FROM THE

INTERNSHIP
Primarily when in third month duration I have got knowledge about different things and also I
developed the theoretical knowledge in to practical knowledge by understanding the science
parallel with it. In general the following skills are some of the skills that I get from stay will be
obtain with duration of the internship program.
4.1 In terms of improving our practical skills

Investigate organizational cultures and work habit of a factory.
Understanding methods of laying raw material in bale store.
Identifying different parameters specification while buying raw material (i.e. cotton)
I have seen different way of raw material mixing in blow room.
Knowing reason of mixing and its advantage.
I have also consolidated knowledge to distinguish and analyzed cotton quality control
before starting the process.
I have also knowledge about working principle and sequence of operation of spinning
and weaving.
Understanding machine maintenance requirement and working procedures.
Identifying most frequently faced portion and gave immediate response.
Knowing about waste water treatment method.
4.2 In terms of up grading theoretical knowledge

Our theoretical knowledge is up grading with the internship period through;
Safety rule of each operation.
Methods of problem identification and way of response.
Referring different manual of machine.
Working mechanism of different machinery.
Passage of raw material in different section.
Identifying parts of a machine which are mainly need series maintenance in different
department.

4.3 In terms of improving inter personnel communication skills

The internship allow as to meet people who may help us land a job later on and give us the
contacts in the industry. Really, I have seen that without effective communication skills, an
employee cannot succeed in the workplace. If communication can fail or if a message can be
understood in different ways, it will be understood in the way which does the most harm.
Generally I have gained the following interpersonal communication skills .I developed:-
Listening skill,
Forwarding precise messages or instructions,
Providing positive reinforcement to subordinates.
I do not dictate or criticize a person's work in front of others and understanding
about their needs,
I interested in the people communicating with me,
I Learn from one another interactions by correcting our faults,
Communicate effectively
Demonstrate social and global competence
Allow me to work effectively with others and generally the inter personnel
communication skill used to strengthen employ moral and loyalty.
Improve meeting productivity resolve work place conflicts effectively
Reduce office stress and absenteeism.
Building positive group spirit.
Improve work place moral with none violent.
4.4 In terms of improving team playing skill

Sharing and being open mind for others idea and preferring working by group is
better than a work done a single.
Ability of problem identification
Selecting the most appropriate method to solve the existing problem.
Generating or forwarding flexible premise to solve the problem arises.
A good decision maker, ability to persuade others etc.

4.5 In terms of leadership skill

Leadership, a critical management skill, is the ability to motivate a group of people toward a
common goal. These items will help me to develop our skills as a leader;
Getting and giving information
Understanding group needs and characteristics
Knowing and understanding group resources
Managing the group
4.6 In terms of understanding about work ethics related issue

As an engineer I have seen that the decisions made will cost too much if they are not
appropriate.
My work habit must be change always being eager to know something new should be
my habits. I developing the work habit
Give respect and love for my job love my discipline when I have seen on the practical
world and being punctual.
Develop importance of unity in working place
Consolidate the behavior of being diligent.
4.7 In terms of improving entrepreneurship skills

I have also learned from the internship skills .there are many entrepreneurs in the company that
they improve recipe of sizing and chemical finishing with lower cost. Finally they have got
reward from the company. In general I strongly recommended printing; sizing, preparatory
process and finishing area in textile are some of major area for entrepreneur. Because it needs
lower costs and less energy consumption.
A person being entrepreneur they should have the following characteristics.
Risk taker Self confidence
Creativity Commitment
Innovative Hard work
Advantages of entrepreneurship;
To properly utilize the resource.
Proper utilization of human potential.
To achieve economic development of the region

4.8 Challenges I have faced while performing our work tasks

When the machines were maintained the technicians were not interested to work
with me and at the time when I asked to show me the electrical and mechanical
components.
There are also a communication problem with operators and technicians,
operators run the machine by long time experience and they have no more
knowledge about mechanism of operation of the machine, this makes the way
so difficult to get information about certain machine.
Some manuals are written in Italian language, this makes a challenge to get
information about specific machine.
There are no enough computer accesses in the company.
Most of the company machine working manually.
Transportation problem
Advisor was not coming and giving me some guidance.
4.9 Measurements taken to overcome these challenges

To smoothly contact to all workers.
To ask the department head about some problems and taking his advice.
By studying different manuals in the library and by asking senior Forman
technicians that work in the factory.
At work I try to approach each worker to make them open to share their knowledge
and skills.
I also try to consider my selves one of the responsible worker in the factory and
accept all work ethics and rule of the factory
I try to contact the company managers and told them about the transportation and the
allow me to use the company workers bus for only one time per day.

5. CONCLUSION AND RECOMENDATION

5.1 Conclusion
During this internship I met many kinds of personnel. Some were really voluntary they teach my
things I do not know, welcome my with great spatiality, and take care like I were work there for
a long time. I gained a lot of experience from those people. While staying for four months in the
factory, I have seen different three phase AC motors with their internal parts and, different
machines with their operations and how to maintain them based on their problems using wiring
diagram from the manual when complex problem arises. Also I have got a chance to see most
abundantly applied power and control circuit connection diagram of motors using contactor,
relay, different switches and timer circuit in the factory such as: direct on line, star-delta and
forward-reverse connections dynamic break and sequential motor control .Consequently, I have
lucky to be in Hawassa textile share factory, because I have gathered much knowledge about
what I have studied in class. And there are things that I have to apply what I learn in order to
achieve the goal. Overall I have very happy with our internship period to gain many valuable
experiences from this internship.
The project is aimed to enable the company to have good controlling systems and in turn it
increase efficiency and sustainability of the system. The biological method of wastewater
treatment significantly reduces the cost of the company expenses per year that pays for different
chemicals used for the wastewater treatment. In addition to these using biological or using algae
wastewater treatment is powerful in treating the wastewater more than using chemicals.
Generally speaking using the algae for wastewater treatment in textile industries saves the
company from expenses of much money. Using the sematic PLC s7-300 controller is best in
reducing maintenance costs and if faults are happened detection and correction is easier than the
previous manual control system. Hopefully using the PLC s7-300 controller provided good
human machine interface and simple to detect faults and is simple in varying parameters.

5.2 Recommendation
Recommendation for the company
Concerning on whole internship program I recommended the following in Host
Company.
The money that earn for workers are low with respect to others. So the company accepts
the question of the worker to increase the money before the worker left the company.
In the time of production some workers not do well, so supervisors should manage the
activity of workers continuously as well as fulfill his/her responsibility.
Medical facilities are given in small considerations but such facilities should be given in
good way.
There are also problems in workers regarding to respecting of work time or on
punctuality. Therefore, it should be proper.
The company should plant good air conditioning system for worker in order to get
refreshed air during working time. It should help workers to fulfill their responsibilities
effectively.
They should write their vision, mission and values of company in front of entrance,
instead of put document in the training office.
Provide enough manuals for interns including 3D view for the example sometimes they
place form works in inappropriate area.
They should provide office for interns and pay pocket money.
Recommendation for university
Universities are providing good opportunities for students in this internship program. But I
would like to recommend my University to do the following during the whole academic
session.
The university should have sent the students to different company in order to
finish their internship program timely.
The university should strive more on quality of education by preparing good
facilities like laboratory, library, work shop and others.
The teaching learning method shall be more practical other than theoretical, for
that to make the students full confident and good expert in the field of study.

The existing wastewater treatment has no well design in automatic. And its running cost is so
high so due to this we recommended them to design this based on the following key points:
1. The existing chemical based wastewater treatment should replace by biological wastewater
treatment.
2. In the thickening tank there is no ultrasonic sensor to detect the presence of sludge, so they
should add this one.
3. In the presence of the wastewater treatment, the controller is in manual, so it should be in
automatic (sematic PLC S7-300 based).
Finally what we conclude to all who have well interested to do on this project, they can
improve this project by adding some software such as Wincc and Human machine interface
(HMI). This project also can extend and implement in different textile factory and leather
factory.

Reference
[1]. Trading as Enviroflow, Enviroflow Biofilter Wastewater Treatment Plant Brochure.
[2] Del Porto D., SPC Workshop on The Soltran II Non Polluting Biological Toilet and
Wastewater garden, Suva, Fiji, 25 November 1996.
[3]. Environ-Technology Inc., 1998. Cromaglass Wastewater Treatment Systems
[4]. Environment Equipment Pty Ltd. Rota-Loo Composting Toilet Brochure.
[5]. Environment Equipment Pty Ltd. Biolet Composting Toilet Brochure.
[6]. Gough I., Langford M., and Gough A. 1999. The Hybrid Toilet System: General Principles
and System Design Drivers. Published by Lanfax Laboratories, Armidale NSW.
[7]. Gough Plastics Australia, the Hybrid Toilet System Brochure.
[8]. Khan, A.R. 1995. Appropriate Wastewater Treatment Processes for N-WFP, Pakistan,
Master of Science Research of Loughborough University of Technology.
[9]. Loetscher T., 1998. SANEX Sanitation Expert Systems
[10]. Ludwig, S. 1998. DEWATS Decentralized Wastewater Treatment in Developing Countries,
Bremen Overseas Research and development Association, Bremen.
[11]. Mann, H.T., Williamson, D., 1982. Water Treatment and Sanitation, Intermediate
Technology Publications 1973, 1979, 1982. Printed in England by The Russell Press Ltd.,
Nottingham.
[12]. Mara, D. Sewage Treatment in Hot Climates, a Wiley Interscience Publication, John Wiley
and N.Sons.
[13]. Neptune Pacific Ltd., On-site and Small Community Sewage Management with the N-DN
Biofilter Treatment Plant
[14]. Pickford, J., 1991. The Worth of Water. Technical Briefs on health, water and
sanitation.
[15]. Sinclair, Knight, Metz, 1997 Review of Effluent Management Systems Castaway
Resort.
16. Hawassa textile share company magazine.
17. Daily reports from company.
18. Electrical material and electrical machines book.


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DTU/FOT/ECE- ICS/2009 EC

Date of Submission: March 13, 2017

INTERNSHIP REPORT BY TEMESEGEN ERMIAS Page i

INTERNSHIP REPORT BY TEMESEGEN ERMIAS Page i

INTERNSHIP REPORT BY TEMESEGEN ERMIAS Page ii

Executive Summary ...................................................................................................................................... ii

List of Figures ............................................................................................................................................... v

List of Tables ............................................................................................................................................... vi

List of Abbreviations .................................................................................................................................. vii

1. BACK GROUND OF HAWASSA TEXTILE SHARE COMPANY ...................................................... 1

1.1 History of the company ......................................................................................................... 1

2.1 INTRODUCTION ................................................................................................................. 9

2.2 Objective ............................................................................................................................. 10

3.1 Getting and Visiting the Company ...................................................................................... 20

INTERNSHIP REPORT BY TEMESEGEN ERMIAS Page iii

Sections in spinning department ............................................................................................ 21

4.1 In terms of improving our practical skills ........................................................................... 46

4.9 Measurements taken to overcome these challenges ............................................................ 49

INTERNSHIP REPORT BY TEMESEGEN ERMIAS Page iv

INTERNSHIP REPORT BY TEMESEGEN ERMIAS Page v

INTERNSHIP REPORT BY TEMESEGEN ERMIAS Page vi

INTERNSHIP REPORT BY TEMESEGEN ERMIAS Page vii

1. BACK GROUND OF HAWASSA TEXTILE SHARE

1.2 Main Service of the organization

INTERNSHIP REPORT BY TEMESEGEN ERMIAS Page 1

Attainable physical capacities (annum)

100% cotton 8.44 million square meters

INTERNSHIP REPORT BY TEMESEGEN ERMIAS Page 2

INTERNSHIP REPORT BY TEMESEGEN ERMIAS Page 3

INTERNSHIP REPORT BY TEMESEGEN ERMIAS Page 4

Over all work Sections of the Company

Plan and Quality Commerce Finance Human and Production

Cost and Man power Spinning

INTERNSHIP REPORT BY TEMESEGEN ERMIAS Page 5

SPINNING WEAVING FINISHING GARMENT

Figure1. 2 Overall work sections of the company

INTERNSHIP REPORT BY TEMESEGEN ERMIAS Page 6

s/n Raw material Name of suppliers Distance from the Remark

Ports and their distance from the factory

s/n Name Distance

INTERNSHIP REPORT BY TEMESEGEN ERMIAS Page 7

1.3 Objectives of the Internship

1.4 Scope of the Project

INTERNSHIP REPORT BY TEMESEGEN ERMIAS Page 8

2. PROJECT AND CONTRIBUTION

INTERNSHIP REPORT BY TEMESEGEN ERMIAS Page 9

INTERNSHIP REPORT BY TEMESEGEN ERMIAS Page 10

Controller Actuator Process Output Output

Figure2. 3 Simple closed loop controls

INTERNSHIP REPORT BY TEMESEGEN ERMIAS Page 11

Figure2.4 Timer block diagram

INTERNSHIP REPORT BY TEMESEGEN ERMIAS Page 12

Figure2. 5 Siemen PL S7-300

INTERNSHIP REPORT BY TEMESEGEN ERMIAS Page 13

Figure2.6 Basic components of PLC

Sensor input PLC Output

INTERNSHIP REPORT BY TEMESEGEN ERMIAS Page 14

INTERNSHIP REPORT BY TEMESEGEN ERMIAS Page 15

The overall waste water treatment process:-

Screen Heat Waiting Fine Biologica

Sludge tank Thickening tank Sedimentation

Figure2. 8 General process block diagram of waste water treatment

2.5 Literature Review