INDUSTRIAL TRAINING REPORT

STUDENT'S NAME

SANA'A UNIVERSITY

FACULTY OF ENGINEERING

MECHATRONICS ENGINEERING DEPARTMENT

NAME OF THE COMPANY

Shamlan Water Industry

January, 2020
Mechatronics Industrial Training

ACKNOWLEDGEMENT

As students of Mechatronics department, we appreciate our department for

all hard working they do to build a comfort zone for students. We thank our
department represented by the head Dr. Abdul-Malik Moamen and the rest of
Mechatronics members for offering us supports to get huge knowledge in this field.
We also thank Shamlan industrial team who provided this opportunity especially
Eng. Mohammed al-Qadi – Head of Electrical section in Shamlan industry.

ABSTRACT
This Report is made up based on our training during two complete weeks
which were challenging and hard time for Yemen and the whole world due to
epidemic COVID-19.This report summarizes our training in Shamlan industry
and containing theoretically and actions that have been taken during training times.

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Table of Contents Pages NO.

1 Introduction
1.1 About Shamlan ………………………………………………….…4
1.2 Shamlan Products Overview…………………………………..4
1.3 Production Lines ………………………………...…….….....….5
2 Electrical
2.1 Introduction for Electrical Section in Shamlan………….6-7
2.2 Electrical Problems and solutions ……………………………7
3.3 Maintains (Daily/Weekly)…………………………...7

3 Mechanical
3.1 Introduction for Mechanical Section in Shamlan
3.2 Mechanical Problems and solutions
3.3 Maintains (Daily/Weekly)

4 Safety
Comments on general safety in Shamlan

 Certificates

REFERENCES

1. Shamlan Official Website

2. Production Line Machine Kroness Website www.krones.com

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1 Introduction

1.1 About Shamlan

Shamlan Company also known as Arwa Mineral Water Company, is considered to be
the one leading and very well-known water company in Yemen. It has been established in
1978. The selection of Shamlan area - called related to the area itself – was based on many
reasons including the supply of pure and natural water. With high international quality and
purity, Shamlan becomes the best water or majority in Yemen. Randomly, samples are
taken to laboratory for test purity of water and so on. Shamlan has given certificates
attesting to the high quality and purity. The company was awarded the European Great
Prize of quality couple of times. One from Madrid in 1988, the other from Geneva in 1988.

1.2 Shamlan Products Overview

Unlike Hadda, and other water company Shamlan has a natural resource for its water
due to its area where it is located and Surrounded by mountains of Wadi -Dhaer which
gives the best quality of pure natural Water.

Shamlan has three production lines to produces water in two different size of bottles:
Small bottles and Large bottles.

1.3 Production Lines

As we mentioned earlier, the industry contains three lines for produce bottles, fill water in
and packing them. The production lines is from Krones, a Germany company that are
famous for process millions of bottles, cans and specially shaped bottles everyday by its
machines and lines. Krones was founded in 1951, Krones offers their customers all
machines and lines, as well as the components, intralogistics and IT solutions that
customers need for their production.
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For more info visit: www.krones.com

Beside Krones, there is another Italian machine for ordering and moving the packages (4
packages up each other).

 Basic Production Lines operations: The beginning is the forming of bottles (capsules).
Capsules are taken throw a stage of high temperature up to 3000 W (heated by 13 heaters,
each heater has 9 leds). In this operation many unwell formed capsules are taken out before
continue the operations in production line. After capsules are have a bottle shape and size
that we know and become ready to be fill, they go to “fill stage”.

Fill stage is about filling water in bottles sequently.We noticed here a problem which is level
of filling is not equal with all bottles and we will point to this problem later. Next stage is
labeling and marking on bottles.

The labels are rolled with two rolling machines (one is permanent and the another one is a
secondary). Labels are marked by color (where it should be cut) so the color sensor gives signal
to the knife and cut equally labels for each bottle. The glue that used for labels needs a heat
165℃. Last stage is the packaging.

Packaging line is sorting bottles by specific numbers of bottles that has to be packed (20
bottles for each package). There is a machine produces air with high pressure that helps to pull
boxes and cover bottles.

2 Electrical

2.1 Introduction for Electrical Section in Shamlan

Electrical section was important to focus on since the industry contains different machines that
worked electrically. We met different engineers with different experiments and ask them to take
us around the industry and see what is really going on there. Having electrical problems can
make production line stops for at least 8 hours before back again to the work so it is important
for Shamlan Industry to avoid such us problems.

There is a separated warehouse where contains eight big generators, three of them are working
while the rest are off till they need them.

It is important to generate cold and hot water for cooling operation inside the industry.

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Three compressors only one of them are working. The compressor produces pressure 15 bar in
two stages; first 5 bar then 7-9 bar.

The production line is about servos and motors the difference between them is servo doesn’t
need cooling operations since it doesn’t get more heat unlike motors they break down if the heat
gets more than the range.

New Good Information

We noticed that a part of industry

production line “bar” moves electrically
in rotary motion without seeing any
electrical wires show up which can cause
problems in case wires get connected to
each other due to the rotary motion of
the that part of machine! Wires are hidden from inside but each generators
That made us wonder and questioned are connected from up to “pass bar” which
ourselves, how is that? means that wires can be electrically connected by
only touching the bar that rotates.

[Cite your source here.]

 PLC section: The industry is working with industrial PLC which is PLC S-7 300 which is
very important in industrial field. We saw this section with our guide and supervisor
Eng. Mohammed al-Qadi.

Although we noticed the SCADA system wasn’t completely there for examples; they can’t
control the production line from far distances or take any actions by supervisors in case any
of workers wasn’t there.

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3.2 Electrical Problems and solutions

! Problem (1): In the first line there was a problem in one of servos which caused the bottles
go slowly.

Solution (1): Based on the catalog of available servos an read the datasheet ,see the right
servo and servo has changed immediately.

! Problem (2): For each phase of conductor there are two heaters connected. When problems
happen to any of these heaters, fuse will blow. The connection of three phases is a star and the
voltage between two phases is 380V and for neutral is 220V. if one of the two phases stopped
working, the voltage 380V will drop down and the natural point as well, the whole side of one of
the heaters will be disable. In the beginning the solution was by checking which conductor is
disable and taking it out, but that doesn’t help since the problems happen most of time.

Solution (2): Adding five extra conductors so now we have aa new wiring with same control
system for PLC. The catalog of conductors, gave the right control for each
conductor. Now each phase has only one heater instead of two.

3.3 Maintains (Daily/Weekly)

Generators are working for 24 hrs./7days, as part of take care of them, generators are stopped
every 500 hrs. for maintains and oil changes.

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4 Mechanical
It is important to beware of the mechanical parts that found there since the production lines
contains those parts.

3.1 Introduction for Mechanical Section in Shamlan

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5 Safety

 Comments on general safety in Shamlan Industry