NEW AYYU

DIRE DAWA UNIVERSITY
INSTITUTE OF TECHNOLOGY
FACULTY OF ELECTRICAL ENGINEERING
DEPARTMENT OF ELECTRICAL AND COMPUTER ENGINEERING
POWER STREAM
HOSTING COMPANY: ELSEWEDY CABLES FACTORY
INTERNSHIP REPORT
PREPARED BY ID NO
YIBELTAL BERHANU..............................................AKU1202385
SISAY ZEMEDKUN…………………………………AKU1202037
Duration of Internship stay: JUL, 01/10/2024 G.C- SEMP, 8/02/2024G.C
Mentor Name: Mr. DAWI.A (MSc.)
Submission Date: 20/09/2024

ELsewedy Internship report and project / 2024
Dire Dawa institute of technology school of ECE Power stream

Declaration
We are 5th year electrical and computer engineering student of Dire Dawa college of
engineering and technology have undertaken internship experience in EL-SEWEDY
CABLES ETHIOPIA PLC of my hosting company for a period of three months from Julay to
september under the guidance of Mr.Samuel our academic advisor and Mr.Ayana.T our
hosting company advisor.
We clarify that our work is original and compiled according to the internship report writing
guideline.
As the student academic advisor, We clarify that the internship report prepared by the
students is original work and compiled according to the guideline provided by the department
as far as my knowledge is concerned and has not been presented for any other purpose in
other university and all the recourse of material used have been acknowledge is concerned.
Prepared by:
1. Yibeltal berhanu
2. Sisay Zemedkun
Name of Academic Advisor: Mr Dawit.A..................Signature............Date............

Acknowledgement
First and for most I would like to express our thankfulness to the almighty God for helping
us throughout the entire time and experience.We also give a great thanks to t Dire Dawa
College of engineering and technology industry linkage for employing this internship
program and its smooth linkage with industries.
Secondly, We offer my heart gratitude to Mr Ayana.T for his inspiration and guidance in
company, Mr. Samuel .A, human resource manager, for his hospitality when we get into
company for the first time, and all the operators and engineers in company for their
encouragement for my effort to know about the company and technical support for US..
Lastly, we give my gratitude to my advisor Mr..Dawit A for visiting our work and his
guidance for report writing.

Executive summary
This report is about the internship practice in EL-SEWEDY CABLES ETHIOPIA PLC
which is found in dukem.The company established in 2009 on 20,000 square meters area
investing $ 50,000,000.It has its own mission, vision and values .The main products are low
voltage, control and overhead transmission line cables. The main customers of company are
EEPCO, defense engineering and electric world. There are five sections such as metal, low
voltage, drum production, maintenance, and quality control. Of these sections the first three
are production sections in which cables are drawn, stranded, insulated, assembled and
sheathed while the last section is where the cable is tested to be supplied for customer. And
also different machines, machine parts and all machine equipment that are available in
Elsewedy Cables Ethiopian Plc have been discussed throughout this text.
The company has general manager at the top and each section has their own managers.
Cables are manufactured in stages using closed loop and forward –reverse system. Every
cable production process is controlled by program logic control system. There are challenges
faced us and measures have taken. Over all benefit gained from internship practice such as
improving practical skill, enhancing interpersonal communication and understanding work
ethics are included. Finally a project is design to solve the problem identified in the company.

Contents
Declaration.............................................................................................................................................i
Acknowledgement.................................................................................................................................ii
Executive summary...............................................................................................................................iii
Acronyms..............................................................................................................................................vi
CHAPTER ONE......................................................................................................................................vii
BACKGROUND OF EL-SEWEDY CABLES ETHIOPIA PLC..........................................................................vii
1.1 Brief history of company........................................................................................................vii
1.2. Mission, vision and value of the company................................................................................vii
1.2.1. Vision:................................................................................................................................vii
1.2.2. Mission...............................................................................................................................vii
1.2.3. Core values........................................................................................................................viii
1.3. Main products..........................................................................................................................viii
1.3.1. Low voltage cables............................................................................................................viii
1.3.3. Control cables.....................................................................................................................xv
1.4. Main customers of the company..............................................................................................xvi
1.5. Over all organization and work flow of the company..............................................................xvii
CHAPTER TWO...................................................................................................................................xviii
OVERALL INTERNSHIP EXPERIENCE...................................................................................................xviii
2.1 How we get into the company....................................................................................................xviii
2.2 Sections in the company..........................................................................................................xviii
2.2.1 Metal section....................................................................................................................xviii
2.2.3 Armoring process............................................................................................................xxxiii
2.2.3 Quality section.................................................................................................................xxxv
2.2.4 Maintenance section......................................................................................................xxxvii
2.5 How good we have been performing our work task..................................................................xli
2.6 Challenges have been facing while performing work task.........................................................xli
2.7 The measure taken to overcome the challenge........................................................................xlii
2.8 procedures used for cable production......................................................................................xlii
CHAPTER THREE.................................................................................................................................xliii
OVERALL BENEFITS GAINED FROM INTERNSHIP................................................................................xliii
3.1 improving practical and theoretical skill.......................................................................................xliii

3.2 enhancing interpersonal communication.................................................................................xliii

3.3 developing team playing skill...................................................................................................xliii
CHAPTER FOUR...................................................................................................................................xlv
IDENTIFIED PROBELEM AND PROPOSED SOLUTION............................................................................xlv
4.2.3 Literature review...............................................................................................................xlvi
4.13 Cost Break down analysis......................................................................................................lxvii
4.14 Summary of the project.........................................................................................................lxvii
4.15 Conclusion...........................................................................................................................lxviii
4.16 Recommendation.................................................................................................................lxviii
CHAPTER FIVE......................................................................................................................................lxx
CONCLUSION AND RECOMMENDATION.............................................................................................lxx
5.1 Recommendation......................................................................................................................lxx
5.2 Conclusion................................................................................................................................lxxi

Acronyms
LV-Low Voltage HV-High Voltage
KV-Kilo Volt PE-Poly Ethylene
USD-United State Dollar PDCA-Plan, Do, Check, and Act
PLC-Private Limited Company μ-Lay factor
IEC-International Electronics Code L-Lay length
PVC-Polyvinyl Chloride MV-Medium Voltage
BS-British Standard XLPE-Cross Linked Polyethylene
AAC-All Aluminum Conductors
ACSR-Aluminum Conductors Steel Rein Force
EEPCO-Ethiopia Electric Power Corporation
G-Giga
MT-Mega Tone
PLC-programmable logic control

CHAPTER ONE
BACKGROUND OF EL-SEWEDY CABLES ETHIOPIA PLC
1.1 Brief history of company
Due to the huge demand of cables and energy sectors in Ethiopia and the surrounding
markets, El-sewedy Cables Holding Company has taken the strategic decision to invest
50,000,000 USD $ in El-sewedy Cables Ethiopia PLC, the first cables manufacturing plant
established on the closed area of 20,000 square meters, on Bishoftu road, at Dukem Ethiopia
in 2009.
With their roots going back over 70 years, running successfully 23 production facilities in 12
countries in Africa, Europe and Asia, exporting their wide range of high quality and safe
products to more than 110 Countries worldwide; El-sewedy cables are one of the world’s
most experienced manufacturers and considered as one of the oldest & most successful
industrial and trading business groups.
This company is a major manufacturer of low voltage cables up to 1 KV, Control Cables and
overhead transmission lines according to International Electrical Code and other European
standards. Therefore it aims to attain high quality products over the country.
1.2. Mission, vision and value of the company

1.2.1. Vision:
 To be the first choice of customer over the world.
 To be center of excellence leader in cable manufacturing in the world and competent in
EU and pace-setter in research and education.
1.2.2. Mission
 ELSEWEDY CABLES Ethiopia PLC is committed to strengthen its market
leadership domestically and locally in low voltage, control cables and overhead

transmission lines manufacturing sector through providing superior quality cables

produced at internationally competitive costs.
 Exceeding customer expectations 100% of the time for enhancing long term value to
its stakeholders.
 Working closely with diversified corporate sectors caring about serving integrated
energy solutions in an environmentally responsible manner as good citizens of the
communities in which they live and work.
1.2.3. Core values

 Quality product
 High Performance
 Customer focus
 Environmental responsibility
 Team work
 Integrity and trust
 Working safely
1.3. Main products

This company is a major manufacturer of low voltage cables up to 1 KV, Control Cables and
overhead transmission lines.
1.3.1. Low voltage cables

Single Core Cables with Solid or Stranded Copper Conductors and PVC Insulated
(450/750 V)
Figure 1.1 Single Core Cables with Solid or Stranded Copper Conductors and PVC Insulated
(450/750 V)
Description: Soft annealed solid or stranded Copper conductors insulated with PVC
compound rated at 70 °C or 90 °C according to IEC 60227 & BS 6004
Application: For indoor fixed installations in dry locations, laid in conduits, as well as in
steel support brackets.

Single Core Cables, with Stranded Circular Copper Conductors, PVC Insulated and
PVC Sheathed (0.6/1.2) kV
Figure 1.2 Single Core Cables, with Stranded Circular Copper Conductors, PVC Insulated
and PVC Sheathed 0.6/1 (1.2) kV
Description: Soft annealed stranded Copper conductor Insulated with PVC compound rated
at 70 °C and sheathed with PVC Compound layer .Cables are produced according to IEC
60502.
Application: For outdoor and indoor installations in damp and wet locations. They are also
normally used for power distribution in urban networks, industrial plants, as well as in thermo
power and hydropower stations.
Multi core Cables, with Stranded Copper Conductors PVC Insulated and PVC
Sheathed 0.6/1 (1.2) kV
Figure 1.3 Multi core Cables, with Stranded Copper Conductors PVC Insulated and PVC
Description: Multi core cables of stranded Copper conductors are insulated with PVC
compound rated at 70°C, assembled together, and covered with overall jacket of PVC
compound. Cables are produced according to IEC 60502.
Application: For outdoor and indoor installations in damp and wet locations.
Multi core Cables, with Stranded Aluminum Conductors, PVC Insulated and PVC
Figure 1.4 Multi core Cables, with Stranded Aluminum Conductors, PVC Insulated and PVC
Description: Multi core cables of stranded Aluminum conductors are insulated with PVC
compound rated at 70°C, assembled together, covered with overall jacket of PVC compound.
Cables are produced according to IEC 60502.
Application: For outdoor and indoor installations in damp and wet locations.
Multi core Cables, with Stranded Aluminum Conductors, PVC Insulated, Steel Tape
Armored and PVC Sheathed 0.6/1 (1.2) kV

Figure 1.5 Multi core Cables, with Stranded Aluminum Conductors, PVC Insulated, Steel
Tape Armored and PVC Sheathed 0.6/1 (1.2) kV
Description: Multi core cables of stranded Aluminum conductors are insulated with PVC
compound rated at 70°C, assembled together, armored with steel tape and covered with
overall jacket of PVC compound. Cables are produced according to IEC 60502
Application: For outdoor installations in damp, wet locations and where mechanical
damages are expected to occur.
Multi core Cables, with Stranded Copper Conductors, PVC Insulated, Steel Tape,
Armored, and PVC Sheathed 0.6/1 (1.2) kV
Figure 1.6 Multi core Cables, with Stranded Copper Conductors, PVC Insulated, Steel Tape,
Armored, and PVC Sheathed 0.6/1 (1.2) kV
Description: Multi core cables of stranded Copper conductors are insulated with PVC
compound rated at 70°C, assembled together, armored with steel tape and covered with
overall jacket of PVC compound. Cables are produced according to IEC 60502
Application: For outdoor installations in damp , wet locations and where mechanical
damages are expected to occur.
Single Core Cables, with Stranded Circular Copper Conductors, XLPE Insulated and
PVC Sheathed 0.6/1 (1.2) kV
Figure 1.7 Single Core Cables, with Stranded Circular Copper Conductors, XLPE Insulated
and PVC Sheathed 0.6/1 (1.2) kV
Description: Soft annealed stranded Copper conductor, Insulated with XLPE compound
covered with a layer of PVC compound to form the overall jacket. Cables are manufacturing
according to IEC 60502 or BS 7889 Standard.
Application: For outdoor and indoor installations in damp and wet locations. They are
normally used for power distribution in urban networks, in industrial plants, as well as in
Thermo power and Hydropower stations
Single Core Cables with Flexible Copper Conductors and PVC Insulated (450/750 V)

Figure 1.8 Single Core Cables with Flexible Copper Conductors and PVC Insulated (450/750
V)
Description: Soft annealed Copper fine wires bunched together in subunits or stranded
bunched groups into a main unit, which forms the flexible conductor Insulated with soft PVC
at 70 °C or 90°Compound.Cables are produced according to IEC 60227 or BS 6004 Standard.
Application: For indoor fixed installations in dry locations, where particular flexibility is
required and for electrical panel’s connection or for electrical apparatus where they can be
laid in groups around steel sheets.
Single Core Cables, with Stranded Circular Aluminum Conductors, XLPE Insulated
and PVC Sheathed
Figure 1.9 Single Core Cables, with Stranded Circular Aluminum Conductors, XLPE
Insulated and PVC Sheathed
Description: Soft annealed stranded Aluminum conductor, Insulated with XLPE compound
covered with a layer of PVC compound to form the overall jacket. Cables are produced
according to IEC 60502 or BS 7889 Standard.
Thermo power and Hydropower stations.
Single Core Cables, with Stranded Circular Aluminum Conductors, PVC Insulated and
PVC Sheathed
Figure 1.10 Single Core Cables, with Stranded Circular Aluminum Conductors, PVC
Insulated and PVC Sheathed
Description: Soft stranded Aluminum conductor insulated with PVC compound rated at 70
°C and sheathed with PVC Compound layer. Cables are produced according to IEC 60502
standard.
normally used for power distribution in urban networks, industrial plants, as well as in thermo

Multi core Cables, with Stranded, Aluminum Conductors, XLPE Insulated and PVC
Figure 1.11 Multi core Cables with Stranded Aluminum Conductors, XLPE Insulated and
PVC Sheathed 0.6/1 (1.2) kV
Description: Multi core cables of Stranded Aluminum conductors are insulated with XLPE
compound, assembled together and covered with an overall jacket of PVC compound. Cables
are produced according to IEC 60502 standard.
normally used for power distribution in urban networks, in industrial plants as well as in
Thermo power and Hydropower Stations.
Multi core Cables, with Stranded Copper Conductors, XLPE Insulated, Steel Tape
Figure 1.12 Multi core Cables, with Stranded Copper Conductors, XLPE Insulated, Steel
Description: Multi core cables of stranded copper conductors are insulated with XLPE
compound, assembled together, armored with steel tape and covered with an overall jacket of
PVC compound. Cables are produced according to IEC 60502 standard.
Application: For outdoor installations in damp wet locations where mechanical damages are
expected to occur.
Multi core Cables, with Stranded Aluminum Conductors, XLPE Insulated, Steel Tape
Figure 1.13 Multi core Cables, with Stranded Aluminum Conductors, XLPE Insulated, Steel
Description: Multi core cables of stranded Aluminum conductors are insulated with XLPE
compound, assembled together, armored with steel tape and covered with an overall jacket of
PVC compound. Cables are produced according to IEC 60502 standard.
expected to occur.

Multi core Cables, with Stranded Copper Conductors, XLPE Insulated, Steel Wire
Figure 1.14 Multi core Cables, with Stranded Copper Conductors, XLPE Insulated, Steel
Wire Armored and PVC Sheathed 0.6/1 (1.2) kV
Description: Multi core cables of stranded Copper conductors are insulated with XLPE
compound, assembled together, armored with steel wires and covered with an overall jacket
of PVC compound. Cables are produced according to IEC 60502 or BS 5467 standard.
expected to occur.
Multi core Cables, with Stranded, Aluminum Conductors, XLPE Insulated, Steel Wire
Figure 1.15 core Cables, with Stranded, Aluminum Conductors, XLPE Insulated, Steel Wire
Description: Multi core cables of stranded Aluminum conductors are insulated with XLPE
compound, assembled together, armored with steel wire and covered with an overall jacket of
PVC compound. Cables are produced according to IEC 60502 or BS 5467 standard.
expected to occur.
Multi core Cables, with Stranded, Copper Conductors, XLPE Insulated and PVC
Figure 1 16 Multi core Cables, with Stranded, Copper Conductors, XLPE Insulated and PVC
Description: Multi core cables of stranded Copper conductors are insulated with XLPE
compound, assembled together and covered with an overall jacket of PVC compound. Cables
are produced according to IEC 60502 standard.
Thermo power and Hydropower Stations.

1.3.2. Overhead transmission line cables

All Aluminum conductors (A.A.C)
Figure 1.17 All Aluminum conductors (A.A.C)

Description: Hard drawn Aluminum wires, stranded in successive layers, in opposite
direction to form the Aluminum stranded A.A.C. conductor as per BS EN 50182 or IEC
61089 standard.
Application: All Aluminum bare conductors are used for aerial distribution lines having
relatively short spans, aerial feeders and bus bars of substations.
Aluminum conductor steel reinforced (A.C.S.R)
Figure 1.18 Aluminum conductor steel reinforced (A.C.S.R)

Description: layer of Aluminum conductor concentrically stranded over the central core of
galvanized solid or stranded steel wires to form Aluminum steel reinforced conductor as per
BS EN 50182 or IEC 61089 standard.
Application: A.C.S.R conductors are widely used for electrical power transmission over long
distances, since they are ideal for long overhead lines spans. They are also used as a
messenger for supporting overhead electrical cables.
Bare Soft and Hard Drawn Copper Stranded
Figure 1.19 Bare Soft and Hard Drawn Copper Stranded

Description
 Plain bare soft drawn Copper conductors as per IEC 60228 class 2
 Plain bare hard drawn Copper conductors as per DIN 48201
Application
 Soft drawn Copper conductors are used for grounding electrical systems, where high
conductivity and flexibility are required.
 Hard drawn Copper conductors are also used in overhead electrical distribution
networks.

Aluminum Conductors & XLPE Insulated
Figure 1.20 Aluminum Conductors & XLPE Insulated

Description: They are composed of one or more insulated conductors and one neutral (bare
or insulated.) They are required as two (Duplex) or three (Triplex) or four (Quadruple)
conductors, XLPE insulated with 2.5 % Carbon black
Application: They are used for secondary over head lines (in circuits not-exceeding 600
volts phase to phase) on poles or as feeders to residential premises.
1.3.3. Control cables

Solid copper conductors, PVC insulation, PVC sheathed
Figure 1.21 Solid copper conductors, PVC insulation, PVC sheathed

Applications: For outdoor and indoor installations in damp and wet locations, connecting
signaling and control units in industry, in railways, in traffic signals, in thermo power and
hydropower stations. They are laid in air, in ducts, in trenches, in steel support brackets or
direct in ground, when well protected.
Stranded copper conductors, PVC insulation, Copper tape screened, PVC sheathed
Figure 1.22 stranded copper conductors, PVC insulation, Copper tape screened, PVC
sheathed
Application: For outdoor installations in damp and wet locations, connecting signaling and
control units in industry in railways, in traffic signals, in thermo power and hydropower

stations. Where electrical interference could alter signal transmission. They are laid in air, in
ducts, trenches, in steel support brackets or direct in ground, when well protected.
Stranded copper conductors, PVC insulation, steel tape armored, PVC sheathed
Figure 1.23 stranded copper conductors, PVC insulation, steel tape armored, PVC sheathed
Application: For outdoor and indoor installations in damp and wet locations, laid Direct in
the ground, where mechanical damages are expected to occur. They are normally used in
connecting signaling and control units in industry, in railways, in traffic signals, in thermo
Stranded copper conductors, PVC insulation, steel wire armored, PVC sheathed
Figure 1.24 stranded copper conductors, PVC insulation, steel wire armored, PVC sheathed
Application: For outdoor and indoor installations in damp and wet locations, laid direct in
the ground, where mechanical damages are expected to occur. They are normally used in
connecting signaling and control units in industry, in railways, in traffic signals, in thermo
1.4. Main customers of the company

 EEPCO
 Defense engineering
 Electric world
 Power engineering (midroc plc.)
 Sigma electric plc.
 Dama trading plc.
 Sunshine construction plc.

 Ethio crown cork plc
 ZF building and electrical mater plc
1.5. Over all organization and work flow of the company
General Manager
H.R Factory Finance

Quality Purchasing Sales and Warehause
Manager manager manager marketing manager
Manager Manager
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CHAPTER TWO
OVERALL INTERNSHIP EXPERIENCE
2.1 How we get into the company

On June 24, 2016 the letter was submitted to EL-SEWEDY CABLES ETHIOPIA PLC and
on next day the human resource manager Mr. Samuel gave me orientation about the
company’s feature and work process. Then on next day, he introduced for practice and each
production section supervisors to inform about all the sections that are involved in the
production and manufacturing process. We have been working in four sections by groups.
2.2 Sections in the company

There are five sections in the company and all section has its own process. These sections are
metal, low voltage, quality control, maintenance and drum production. But we were
performing our tasks in only first four sections.
2.2.1 Metal section

This section is a place where the manufacturing of cable in the factory starts. Generally there
are two main processes carried out in the metal section of the factory.
1. Drawing section: the area at which drawing process take place
2. Stranding section: the area at which stranding process carried out
There are two types of metals used as a raw material in cables manufacturing:
 Copper /Cu/ with Diameter 8mm and weight (3-4) ton
 Aluminum /Al/ with Diameter 9mm and weight 1.5 ton

Copper Rod
Application: Copper rod specified by the following standard is mainly used for electric
cables; were conductors drawn as soft or hard. This rod is drawn to minimum size of 0.2mm
diameter.
Standards: The latest edition of the following standard is applicable.
 BS EN 13601
 BS EN 1977
Requirements:
 Size: copper rod shall be of round cross sectional area of 8mm diameter with
±0.38mm as tolerance.
 Electrical properties:
 Minimum conductivity of 101% IACS
 Maximum electric resistivity shall not exceed 17.07 ohm.mm2/km at 200c
 Mass resistivity shall not exceed 0.15176ohm.g/m2 at 200c i.e density shall
not exceed 8.89G/mm2/M at 200c
 Mechanical properties:
 Minimum tensile strength is 200N/mm2
 Minimum elongation 35%(in 250mm)
 Chemical properties:
 Surface oxide to be less than 400Å
 Finishing and appearance: Copper rod should be supplied in form of rose coiler
coils in one continuous length without any kind of joints. Rod should be clean,
smooth and free from pipes, twists seems, damage ends, excessive oil and other
injuries.
 Packing and marking: The copper rod coil should be of maximum diameter of 2.0m
and of maximum height 1.0m. Each coil weight should not exceed 4.5MT and not
less than 3MT.

Acceptance test: The following tests and checks are conducted as acceptance test.
 Appearance checks
 Diameter measurements
 Electrical properties
 Mechanical properties
 Density
 Surface oxide
 Chemical composition analysis(first time supply)
Aluminium Rod
Application: Aluminium rod is mainly used for the underground and over head cable
conductors. This rod is drawn to minimum size of 1.05mm diameter.
Standards: The latest edition of the ASTM B233 standard is applicable
Requirements:
 Size: Aluminum rod shall be of round CSA of 9.0mm diameter with ±0.3mm as
tolerance or 9.5mm diameter of with ±0.5mm as tolerance.
 Electrical properties:
 Minimum conductivity of 61.5% IACS
 Maximum electrical resistivity shall not exceed 28.035ohm.mm2/km at 20oc.
 Mechanical properties: Tensile strength should range from 8.5 up to 11.9 kg/mm2
 Finishing and appearance: Aluminum rod should be supplied in form of coils in

one continuous length without any kinds of joints. Rod should be clean, smooth and
free from excessive oil, damaged ends and other defects.
 Packing and marking: The Aluminum rod coil should be of maximum diameter of
1.5m and of maximum height 1.0m. Each coil weight should not exceed 2.3 ton and
not less than 1.8 ton.
Acceptance Test: The following tests and checks are conducted as acceptance test:

 Appearance checks
 Diameter measurements
 Electrical properties
 Mechanical properties
 Density
Raw Diameter Elec. Tensile Elongation Weight

material (mm) Resistivity(Ω. Strength(Kg/ (g/mm2/
m2/Km) mm2) m)
AL.H12 9 28.264 8 : 10.5 20% 2.7
AL.H14 9 28.264 10.5:14 15% 2.7
Copper 8 17.241 Max. 250 40% 8.89
Table 2.1 properties of raw material used in the factory

Notes:
 The max. Tensile strength of the copper means the maximum force that can apply
over cross section area.
 Low efficiency of conductor when Elongation and Cross sectional area increasing
because the resistance will increase too.
Copper /Cu/ Aluminum /Al/

Low specific resistance About 40% higher specific resistance
Good conductor of electricity with small Good conductor of electricity with large
CSA CSA
Heavy in weight Light in weight

More expensive Cheaper than copper
Best for cables required for high stresses Best for cables required for flexibility
Mainly used for underground cables Mainly used for underground cables
Table 2.2 comparison between copper and aluminum conductor cable

Drawing process
Drawing is a mechanical deformation process carried out as the metal is below its re-
crystallization temperature, to reduce the wire diameter by tension force. This has two main
functions:
i. It gives the required shape to the metals
ii. It improves the mechanical properties of metals by refining the structure
Here in the drawing section, between 17 and 33% of the initial diameter can be reduced by
passing the wire through a series of dies with certain sequence till we get the required
diameter.
T
Figure 2.1 drawing process

Calculation of reduction ratio or Elongation;
From conservation of mass theory the mass of cable before and after drawing is constant
therefore;
Mass 1 = Mass 2
ρ.L1.A1= ρ.L2.A2
L1.π/4.D12=L2.π/4.D22
L2=L1+ΔL
L1D12= (L1+ ΔL).D22
D12/ D22= (L1+ ΔL)/ L1=1+Σ%
Σ%= D12/ D22 - 1
Where
Σ-Reduction ratio or Elongation

D1-Diameter of wire before reduction process

D2-Diameter of wire after reduction process
From the final equation if the reduction ratio is known; one can calculate the die size of all
stages.
Main component of drawing machine
 Pay off
 Drawing block
 Final capstan block
 Annealing machine
 Dancer
 Take up
Final capstan block Annealing machine
Pay off Drawing block
Take up Dancer
Figure 2.2 drawing machine block diagram

1. Pay off: It is the first stage in the drawing process; its function is to take row material to
the second stage.
2. Drawing block: It is the main part of machine where the drawing process takes place; the
function of this machine is to reduce the diameter of conductor through a series of dies.
3. Final Capstan Block: The function of the last capstan is to be sure that the diameter of
wire not changed, to reduce the cut of wire and the number of turns in technical
recommendation catalog.
4. Annealing Machine: Since the drawing process done is cold working drawing operation,
the grain structure changes. The deformation takes place when the applied stress exceed the
elastic limit during cold pressure when severe stresses known as residual stresses are
developed in the metal. This stresses can be removed by suitable heat treatment known as
annealing. Annealer exists only in copper wire drawing process. This operation is

temperature process for copper metal after drawing operation done by increasing the heat to
50 degree; but isolating system from air to decrease the hardness and retain material
properties of copper again because its property is changed in the drawing process.
5. Dancer: it is constructed from two capstans, pneumatic system, and its function is to make
synchronization speed between take up and the feed speed of drawing block.
6. Take up: It is a basket or bobbin that is used to hold coils.

Types of Drawing Machines
There are basically two types of drawing machine used in the factory.
a) Heavy drawing machine
 Copper drawing machine
 Aluminium drawing machine
b) Intermediate drawing machine for flexible copper
Kinds of machine
Items Intermediate Heavy drawing Heavy drawing machine aluminium
drawing machine copper
machine
Max. No of dies 14 13 15
Min. diameter(mm) 0.26 1.2 Inlet diameter Outlet diameter
9.5 9
1.7 1.53
Max. diameter(mm) 1.35 4.5 Inlet diameter Outlet diameter
9.5 9
4.5 5.2

Max. speed(m/s) 30.05 31.5 37.5

37.5
Table 2.3 types of drawing machine

Stranding process
The need of making the stranding operation is that:
 The current flows typically along the surface of the conductor (skin effect).so, to
allow the conductor to carry more current; more wires of smaller cross-sectional areas
are used instead of using just one of larger area. In this way, conductors are made of
layers of wires. The conductor of cables consists of a number of strands of wire of
circular cross section so that it may become flexible and carry more current.
 To avoid the bending and deformation of the conductor under normal conditions.
The numbers of wires in stranded cables are: 7,19,37,61,127 and 169.
Figure 2.3 stranding process
Lay length: It is the distance (in mm) between two consecutive ups or downs of a certain
component of the cable. Lay length = ϕ final conductor x Factor
Conductor Factor
91 8-10
61 10-12
37 12-14
19 14-16
7 16-18

Table 2.4 number of wires and their factor
Calculation method of circular conductor diameter is by this equation; Dc = μ.Dw

Where; Dc- the diameter of conductor of the cable
Dw- the diameter of the wire, μ- Lay factor
Stranding Cables
A. Sector cable ( used for low voltage range of 3 X 120 – 4 X 90 – 3 X 100 + 60 )
B. Round cables
C. Compact round
Classification of stranding machines
Figure 2.4 Rigid stranded machine

Rigid stranding machine: This machine has
a capacity of stranding up 61 wires but in this
factory it can strand a maximum of 37 wires.
The machine consists of:
Feeding carrier.
 Rotating cage contains 6 pulley carriers.
 Rotating cage contains 24 pulley carriers
 Double capstan of diameter 2m.

 Receiving carrier. Figure 2.4 Rigid stranded machine
 Rollers after each cage used in compact and sector conductor.

2. Double twist machine.
This machine strands the wires by using a rotating arm which rotates fast twisting the wires,
and then the wires are reversed to be turned on the receiving pulley which rotates around
itself and that is the other twist.
3. Tubular stranding machine
It is seven wire, both copper and aluminum, stranding machine used to strand wires of small
size.
4. Bunchier stranding machine
This is machine is used to strand flexible wires drawn by intermediate drawing machine. It
can strand up to 14 wires bobbins as pay off.
2.2.2 Low voltage section
There are five process made in this section
1. Insulation
2. Assembly
3. Bedding
4. Armoring
5. Sheathing
Insulation
There are two types of materials used for insulation in this factory
1. Thermoplastic material: type of material that can be recycled such as Polyvinyl chloride
(PVC)
2. Thermosetting material: type of material that cannot be recycled such as XLPE

The XLPE material consists of PE (polyethylene); with Catalyst material and by operating
condition it is converted to XLPE such that PE + Catalyst → XLPE
Cost Cheaper than XLPE More expensive than

PVC
Recycling yes no

Operating temp. 70°C 90°C
Density From 1.4 to 1.6 g/cm3 0.92g/cm3
Table2.5 comparison of insulation material

Both PVC and XLPE are used as insulation for low voltage cable, while XLPE is also used
just for MV and HV cable. However, the material property of XLPE used in MV and HV is
more pure than in low voltage so it is stronger and more expensive. PVC and XLPE are
colorless by nature. Cables are colored according to the customer needs and the standards. the
basic colors are: red, yellow, blue, and black. The ratio of color is 2% for PVC and between
0.5% to 1% for XLPE. The material used for coloring is called “master batch”.
Properties of cable insulation
 Must have specific resistance.
 Must be high dielectric strength (KV/mm)
 Rigid and flexible.
 Must be nonflammable.
Extrusion Process
Insulation of conductor cable process is carried out in this section. It has two main functions;
 To protect the cable from any behind air
 Insulate the conductor from any other conductor
This section is the most important part of the overall production section. Before starting the
extrusion process great care must be taken on the following part:
 The quality product should be checked at every stage
 The dimension should be standardized
 Cooling system must be checked

Figure 2.5 Extrusion process
Pay off caterpillar extruder Cooling Spark tester

trough
Take up caterpillar
Figure 2.6 insulation machine block diagram

1- Pay off: feed the machine with conductor.
2- Caterpillar: to pull the conductor. There are two caterpillars one at the beginning the
machine and other at the end, the speed of two caterpillar must be synchronized.
3- Extruder: consists of screw, barrel and crosshead. the screw part consists of five zones
which used to heat the insulation material PVC or XLPE before going to the crosshead of the
machine, the head part consists of four heaters
4- Cooling trough: necessary to cool it before going into the reel.
5- Spark Tester: apart that response of the test insulation. its idea is that applied DC voltage
reached to 10 KV to test the insulation of the wire.
6- Take up is the reel that is ready to go to the assembly process.

Extrusion machine used

i. Extruder 80mm
 Processes made : Insulation
 Diameter of the cable from 0.5 mm2 to 10 mm2
 Materials used in this machine : PVC and XLPE
The next conductors are insulated with this machine: stranded, flexible and solid.
 Max. line speed 1000 m/min
 Spark detector is installed to verify that the insulation has no faults.
 Pay off and Take up: two units with reel of maximum diameter of 1000 mm and
minimum diameter of 630 mm and maximum weight of 1 Ton.
 This machine has no caterpillars instead it is using two capstans to apply tension to
the conductor and make the insulation attached to conductor.
ii Extruder 120mm super Mac(India)

 Pay off and take up of two units with bobbin size of max. Diameter of 2250mm and
min. diameter of 800mm and max. Weight of 6 ton.
 This machine has two caterpillars.
 Processes made : Insulation, bedding and sheathing
 Diameter of the cable: copper or aluminum conductors from 5 mm2 (round) to 57

mm2 (sector or round).
 Materials used in this machine : PVC and XLPE
 Spark detector is installed to verify that the insulation has no faults.
Extruder 120mm
Screw 1 Screw 1
Length/diameter ratio(L/D) 25 25

Maximum rpm 80 rpm 100 rpm
Maximum output PVC 600 Kg/Hr 120 Kg/Hr
Number of heating zone 6 zones 4 zones
Table 2.6 extrusion 120mm super Mac (India
iii.Extrusion 150mm super Mac (India)

 Pay off and take up of one unit with Bobbin size of max diameter of 3600mm, min
diameter 1100mm, and max weight of 20 ton.
 Processes made : Insulation, bedding and sheathing
 Diameter of the cable: copper or aluminum conductors from 11 mm2 (round) to 115
mm2 (sector or round).
 Materials used in this machine: PVC and XLPE, low smoke material ……etc.
 Spark detector is installed to verify that the insulation has no faults

Extruder 150mm
Screw 1 Screw 2
Screw diameter 150mm 600mm
Length/diameter 25 25
ratio(L/D)
Maximum rpm 60 rpm 100 rpm

Maximum output 900 Kg/Hr 120
PVC Kg/Hr
Number of heating 6 zones 4 zones

zone
Breaker plate filter

Table 2.8 extrusion 150mm super Mac (India

Assembly process
The main function of this stage to assemble all phases and neutral together; and covers them
with propylene tape. During this first step all conductors are assembled together in one cable
and after that the cable is covered with polypropylene tape.
Pay off Assembly Correct angle Dies stage

Block
Take up Tape or
armoring
stage
Fig 2.8 assembly machine block diagram
Assembly machines
a. Assembly 1600
b. Assembly 2600
a. Assembly 1600

It is used just for assembling and armoring (steel wire). In the assembly operation, this
machine is used just with round conductors with small sizes, basically control cables, and
made up to 24 phases.
b. Assembly 2600
This machine is used with all kind of process: Assembly armoring (steel wire armoring SWA
or steel tape armoring STA) and screening.
Figure 2.10 assembly 2600 machine
2.2.3 Armoring process

The armoring stage is carried out to protect the cable against any mechanical stresses, for
instance, ground pressure appeared over the underground cable when a big truck is passing
over generating a pressure force through the soil that may reach the cable.

When the cable is working under normal conditions, the current flowing through the
conductors generates a magnetic field which produces current circulating along the layer of
armoring; therefore it needs to be grounded in some point.
Figure 2.11 armoring process

Types of Armoring
1. Steel tape armoring: This type of armoring is carried out basically to protect the cable
against any horizontal mechanical stresses as explained before. Apart from that, it can also
carry the earthlings fault current. This type of armoring is done with two steel tapes by using
an over gap process: The second layer of tape is placed over the first one by 50 % over gap of
the tape width, the size of the tape is specified by its width and thickness by this equation i.e
Tape width x Tape thickness
2. Steel wire armoring (galvanized): This type of armoring is carried out to protect the
cable against strains: the horizontal tensions appeared along the cable. The wires can also
carry the earthling fault current. The operation is carried out by covering all the surface area
of the cable with wire called "Armoring Lay" .one period of wire moving around the cable
can be determined as Armoring lay = factor X diameter of the cable.
Bedding
This process is done right after the assembly process. It is an operation done between stages,
before armoring, and before sheathing.
Sheathing
The sheath is the cover of a cable just used for mechanical protection. This process uses the
same extrusion method as that one used for insulation and bedding. PVC is used as sheathing
material.

Coiling process
Single core cables, insulated by Ex-80 extrusion machine and of size 1.5-2.5, are coiled by
two coiling machine. Cables have pay off and take up. The spool, which is produced in that
company from waste of PVC insulating material, is used as take up. Cables are coiled in
length of 100m and packed by closed loop operated packing machine. Sekora sensor is
available to test insulation fault on the cable being coiled.
2.2.3 Quality section

There are four classes of quality section.
1. Quality assurance
2. Quality control
3. Electrical lab
4. Non-electrical lab
Quality assurance
Quality assurance is the process of verifying or determining whether products or services
meet or exceed customer expectations. This process considers design, development,
production, and services. The most popular tool used to determine quality assurance consists
of four steps: plan, do, check, and act; abbreviated as PDCA.It is an effective method for
monitoring quality assurance because it analysis existing condition and method used to
provide the product or service customer. The goal is to ensure that excellence is inherent in
every component of the process. Quality assurance also helps determine whether the steps
used to provide the product or services are appropriate for the time and conditions. In
addition, if the PDCA cycle is repeated throughout the life time of the product or service, it
helps improve internal company efficiency.
Quality control
Quality control is a process employed to ensure a certain level of quality in product or
service. The basic goal of quality control is to ensure that the products, services, or processes
provided meet specific requirements and are dependable, satisfactory, and fiscally sound. It
can cover not just products, services, and processes, but also people. Employees are an
important part of any company. If a company has employees that do not have adequate skills
or training, have trouble understanding directions, or are misinformed, quality may be
severely diminished. When quality control is considered in terms of human beings it concerns
correctable issues.

In quality control section there are three sections to check the products starting from the raw
material used and during all various production process, till the final stage to ensure the
quality of the products and to confirm the required specification before it shipped to the
customer.
1st stage-raw material test
All raw materials are brought into the stores and placed into the ware house for quality
control to process and test according to materials book and work instruction for each
material. These are then reported as either accepted or rejected.
2nd stage-in process test
The purpose of in process test is to maintain production standards and ensure the compliance
of product with the tolerance set out and manufacturing specification.
I. Wire drawing process: parameters that have to be checked during this process are:
 Elongation test for 10% of the drawn wires
 Tensile strength for 10% of the drawn wires
 Wire diameter for 10% of the drawn wires
 roundness for 10% of the drawn wires
II. Stranding process: parameters that have to be checked during this process are:
 Resistance measurement
 Weight measuring
III. Insulation process test: parameters that have to be checked during this process are:
 Insulation thickness
 Spark test
 Color of insulation
 Hot set test for XLPE insulation

3rd stage-final sheathing
The physical properties measured to check compliance are:
 Thickness of outer sheath
 Cable marking(embossing) or printing

 Spark test
 Color of outer sheath
 Length marking
Electrical lab
This is the final test of quality section. In this lab, physicians test the resistance of cables and
its low voltages (1kv) or its conductivity. However, the test takes place for 1kv, the company
tests up to 3kv for high quality.
Non-electrical lab
In this non-electrical lab, the test takes places are:
 Raw material test
 Type test
 Routine test
2.2.4 Maintenance section

When machine is in operation it may fail electrically and mechanically due to friction and
electrical fault. This section play a vital role in maintaining break down machines and
installing new machines. Both mechanical and electrical Engineers are available in section to
maintain mechanical system and electrical circuits, design dies and install program on
PLC.As mentioned before since , we have spent more time in this section we were practicing
machine starting mechanisms based on the assignments give by our company Supervisor .
Some of Workshop practices we have been performing .
 Direct - Online motor starting method ( DOL )
 Star - Delta motor starting method / Y -
 Reverse - Forward motor starting
2.2.4.1 Direct - Online motor starting method

In this method the polyphaser stater on to the main supply is directly switched Depending on
size and design the motor takes low power factor starting current of 5 to 8 times its full load
current . Such large currents of short duration don't harm the rugged squirrel cage motor , but
the high currents may cause objectionable voltage drop in the power supply lines feeding the
induction motor . These large voltage drops cause , undesirable dip in the supply line voltage

consequently the operation of other equipment's connected to the same supply line is affected
considerably .
Figure2.10 Direct online motor starting mechanism

2.2.4.2 Forward-Reverse motor starting

To change the direction a three phase induction machine rotation , two of its phases needs to
be exchanged , thus changing the phase sequence form , say RYB to BYR . This can be
accomplished by using two contactors , one for the forward rotation and one for the reverse
rotation . The forward and reverse contactors are mechanically interlocked i.e , if one of them
is closed the other cannot close . This is due to moist dead short circuit in contactors closing
simultaneously.
Figure2.11 Forward - reverse motor starting mechanism

2.2.4.3 Star - delta motor starting method

In this starting motor method it employed to provide reduced voltage of start . In this method
the normal connection is delta while running . If these winding's are connected in star at
start , the phase voltage is reduced , resulting in less current of starting . As the motor
approaches its full speed and the winding's will be connected in delta . Star delta connection
also reduces starting torque to one third of that produced by direct switching in delta .
Figure 2.12 Star- delta motor starting mechanism

Drawing Stranding Insulation Insulation Single/ Assem

process Process Required Process multicore bly
Bare Conductor Single Core
Final
Bedding
Inspection Sheeting Armoring Bedding Lead
Process
and Testing
Without load
Finishing
Parking
Goods Store
Figure 2.13 procedures used for cable production
2.5 How good we have been performing our work task

Internship program has a great importance to approve theoretical knowledge by practical one.
So we have been doing we work best without being exhausted and respecting work ethics .
When we execute our tasks the following steps as follow ;
 Identifying the problems
 Identifying what cause the problems
 Then finally solve the problem

2.6 Challenges have been facing while performing work task

 The company were not given safety material
 The environmental condition influence during internship practices were a major

challenge and
 Besides , these during our practice there were some challenges in the factory due to the
failure of different machines.
 It was difficult to get into the company, since they denied training me for the sake of lack
of place.
 We couldn’t cope with machines working principle because they are installed with plc
program.
 The company’s engineers didn’t give me a detail explanation about machines available in
company because they were busy.
2.7 The measure taken to overcome the challenge

 We use our access so as to overcome safety materiel problem .
 We made an effort to know about machines and their working principle asking operators
in the company .
 We tried to communicate smoothly with human resource manager to get into the
company .
 we used safety materials by my self and participated by motivation .
2.8 procedures used for cable production

CHAPTER THREE
OVERALL BENEFITS GAINED FROM INTERNSHIP
3.1 improving practical and theoretical skill

During the internship program, we able to introduce myself with every dynamic working
environment. Since we have been working on different machine parts and equipments; we
improved my practical skills for solving engineering problems. We have seen and tried to
understand the application of materials such as contactor, relay, limitswitch, proxmit sensor,
spark detector, motor drives,plc and potentiometer sensor in machines, and systems i.e.
closed loop and forward-reverse system .we have also deep-rooted our theoretical knowledge
in concurrence with the practical one.
3.2 enhancing interpersonal communication

This internship program played a major role in enhancing my skill of communication with
technicians, operators and company’s workers. After we get into the company, we able to ask
what is new for me politely and they gave me an answer with smile face.
3.3 developing team playing skill

This program has helped we in improving team work on different aspects, for instance, being
cooperative, seeking opportunities for continuous learning, sharing ideas with operators and
each other . These all increase my team working skill.
3.4 gaining leadership skill
We have seen how is important the concept of leadership in any work area. Hence, we tried
to learn:
 How to control the resource and material of the company

 How to manage the workers of the company
 How the leaders interact with workers smoothly and understandable way
we have gained the knowledge of performing one’s responsibility in a good manner and
improved my leadership skill.
3.5 understanding about work ethics and related issues

The concept of work ethics is the overall quality in one’s behaviour towards appreciating the
process of work flow and performing well on the job so that this work flow will not be
jeopardized in the long run. During my internship program, we should say that we have
managed to do my side of the job description with a high sprit and enthusiasm so that there
was smooth flow of activities both in the office and workshops.
3.6 improving entrepreneurship skill
A wide range of skills are seen as entrepreneurial and useful to entrepreneurs , these include
 Management skills ;the ability to manage time and people ( both yourself and other )
successfully .
 Communication skills and the ability to sele ideas and persuade other .
 The ability to work both an part of a team and independently.
 Able as plan coordinate and organize effectively.
 Able to research effectively for example available markets , suppliers , customers and the
competition .
 Self-motivated disciplined.
 innovative thinking and creative.
 the ability multi - task.
 Able to take responsibility and make decisions .
 The ability to work under pressure.
These set of skills are what make a certain individual able to create a brand new set of ideas
that may help in the production process not only in the construction stream but also in any
form of activities that has a certain end product to it. During the program, we were not able to
come up with a whole new set of ideas that were implemented into action. Nevertheless, to
the best of my abilities, we am able to observe and learn the ways and systems that lead to the
creation of a whole new set of ideas to better outcomes on the production process. we have

gained knowledge of entrepreneurship so as to be self confident owner and administrator of

company within its personal workers.
CHAPTER FOUR
IDENTIFIED PROBELEM AND PROPOSED SOLUTION

4.1 PROBELEM IDENTIFICATION
It is know that everything that has benefit come with some problem and same is true for
elsewedy cable ethiopia PLC.so the problem identified in the company is the following;
 Lack of automatic water level controller and motor stoppage alarm limitation of
automatic chiller machine temprature controller
 Frequent fail of electrical motor due to different reason
 Drawback of automatic cable quality checking system
 Shortage of automatic coiling system
 Limitation of automatic system that wind cable on the drum
 Shortage of automatic traverse insulation system during uncoverd wire occur
4.2 Proposed solution
4.2.1 Automatic water level controller and motor stoppage alarm
Hence it is difficult to solve all this identified problem of company simultaneously.due to this
reason we are enforced to propose solution to simulate the project on automatic water level
controller and water stoppage alarm in addition to this problem related to motor starting
mechanism which is star-delta ;it is the most imperative for the company in order make the
pumping motor to work safely .the company the whole process depends on water since the

water is the backbone of factory ;especially in the insulation process and drawing process to
cool the wire.
4.2.2 Background
The company has different System which needs little inter action of human being the
machine in each production section are controlled by plc system installed technicians
and normally brought machines .The company needs water for the different purposes ; for
cooling the conductor after insulation process to protect thyristors from becoming hot that
means the water is used as a heat sink in order for the device to work properly and also to get
steam after boiling water for drawn wire to smooth it. Hence without water the company
would not work and no task can be done it is very important to take good care of the water
pumps safe . But the motor that sack the water from the ground ( submersible ) and the one
which distributes water to the industry are started in DOL , motor starting system this may
damage the motor . To make the motor safe and work long time without damage come up star
- delta starting mechanism will be used and automating water level controller and motor
stoppage alarm are preventing over flow of the water from the tanker and alarming when the
motor stoppage why because the motor found in unsafe place ( 12 ) Waleed , ( 2009 ) , p .
200 ).
4.2.3 Literature review

There are so many methods to know the level of liquid in the container . For instance , in
traditional method ; we can check the level by inserting stick or any material in to the
container or checking simply by hitting the container if there is liquid inside the container or
not . There are many projects done in the control of fluid level with relay circuit and micro
controller . But those control systems are not suitable for an embedded system in large
industries . So , to Overcome this difficulty we done for a company PLC based Automatic
Level Controller and motor stoppage alarming . So , the controlling motor stoppage can
overcome such difficulties like over flow of water , wastage of natural resources and ... Etc.
But the motor stoppage alarm can solve the problem faced in the company by informing to
the operator . Generally , this chapter will cover on the literature review of the project and
further elaborating on that existing device . The technique of liquid level monitoring and
controlling system concentrated with some basic parts.
4.2.4 Statement of problem

Controlling manually water level and motor stoppage is difficult due to pumping motor
located in the well since far away from the user . Due to more time consuming on manual
operation total . If we are unable to continuously monitoring the system , there is a loss of
energy sources for pumping water as well as loss of natural resources by overflowing water
from well . Switch on the pumping when the water in the tank goes to low and switch off the
pumping when water in the tank above high level and starts overflowing . The circuits that
we are using to make this system automatic ; it switches on / off the pump and alarming when
the motor is stop working When the water level in the tanker goes low and switches it off as
soon as the water level reached a pre - determined level . It also prevents ( dry run ) of the
pump in case the level in the tanker goes below the level . With invention of different
technology and automatic system , people want to do such a task without manual touch . For
fulfillment of people desire we have design this system which controls the motor used to
pump water . Motor is automatically starts and stops as the requirements . Our system is not
only water level controlling system but also motor stoppage alarm ; we also implement star
delta motor starting mechanism for safe operation The design approach for this system is
based on PLC controlling system and motor stoppage alarm with water level sensor and
motor stoppage.
4.3 Objectives
4.3.1 General objective
 In order to make water level automatic and motor stoppage alarm sound.
4.3.2 Specific objectives
The specific objectives of this project are :
 To interface level sensor with PLC software
 To simulate buzzer with PLC software
 To simulate valve and pumping motor with PLC Software
 To monitor the system automatically
 To make motor starting mechanism safe

4.4 Significance of project
 Stop overflow of the water and indicate motor stoppage .
 Increase the life times of the motor due to starting mechanism .
 This project will highly minimize the unnecessary costs that the company spends on
purchasing new pump motor.
 controls the high and low level of the water in the well.
 Avoid manually checking of water level in the well .
 Implementing this project will eliminate the wastage of natural resource which is the
water and alarm when the motor is stop working.
 It saves valuable time which wastes at the process maintenance .
 Increase speed of work .
 This project will also prevent any interruption of production process hence water is
crucial to the production held , so the work will go on safely .
4.5 Scope of the project
In order to build this project , the scope is developed to ;
 Develop and analyse classical control circuit of the water level and motor stoppage
alarm .
 Simulate the circuit construction in PLC software .
 Construct control and power circuit in EKTS software .
4.6 Methodology
This project requires procedures for getting information on how each part functions , design
and construction held hardware and software requirements . Hardware such as level sensor ,
buzzer , valve , contactor , relay , switch , pump motor and timer . For successful completion
of this project some steps will be followed to carry out different tasks . Different literature
will be revised relating to this project and data will be collected about condition and control

principles of level sensor , PLC etc. Based on this parameter system model was designed .
Some software's were selected to develop the software programming . So here a system is
designed with two alternative methods using PLC and EKTS . Generally , the methodology is
concluded by the block diagram given bellow . This project is aimed at solving this cable
factory problem by taking into consideration Technology appropriateness , cost can be used
to research problem is described in this section . Problem Identification Concept Generation
System Analysis Design Simulation Evaluation.
Problem Concept System

Analysis Simulation Evaluation
identification Generation Design
gf
Figure4.1 Block diagram of methodology of the system
4.7 Components Used in the Proposed Project
The system automatic water level controller and motor stoppage alarm is composed of
components that are connected to each other to function as desired . Those components are
PLC , switch , valve , timer , buzzer , level sensor , contactor and motor pump . In addition ,
Siemens PLC is used to design and simulate the hardware components listed above . The
details of these components are emphasized below as follows .
 PLC
The National Electrical Manufacturers Association ( NEMA ) defines a PLC ( S7-200 ) as a "
digitally operating electronic apparatus which uses a programmable memory for the internal
storage of instructions by implementing specific functions , such as logic , sequencing ,
timing . counting , and arithmetic to control through digital or analogue I / O modules various
types of machines or processes . Basically it's a solid - state , programmable electrical /
electronic interface that can manipulate , execute , and / or monitor , at a very fast rate , the
state of a process or communication system . It operates on the basis of programmable data
contained is an integr microprocessor based system . A PLC is able to receive ( input ) and
transmit ( output ) various types of electrical and electronic signals and can control and
monitor practically any kind of mechanical and / or electrical system ( 12 ) Waleed ,
( 2009 ) , pp . 210-215 ) .

Therefore , it has enormous flexibility in interfacing with computers , machines , and many
other peripheral systems or devices . It's usually programmed in relay ladder logic and is
designed to operate in an industrial environment ( 12 ) Waleed , ( 2009 ) , p . 216 ) .
A Programmable Logic Controller , or PLC for short , is simply a special compute device
used for industrial control systems . They are used in many industries such as oil refineries
manufacturing lines , conveyor systems , tank level control and so on . Where ever there is a
need to control devices the PLC provides a flexible way to " soft wire " the components
together ( 14 ) Ahmed , ( 2008 ) . p . 450 ) .
The basic units have a CPU ( a computer processor ) that is dedicated to run one program
that monitors a series of different inputs and logically manipulates the outputs for the desired
control . They are meant to be very flexible in how they can be programmed while also
providing the advantages of high reliability ( no program crashes or mechanical failures ) .
compact and economical over traditional control systems ( 12 ] Waleed , ( 2009 ) - p . 239 ).
a ) The basic components of the PLC are the following Power supply
 Input module
 Power supply
 Output module
 Processor
 Programming device
b ) Power supply
It is a part of PLC which supplies power to the components of a PLC . These units step down
the given power to give suitable amount of power to each PLC components ( 3 ) A.Thue . , p .
101 ).
Figure 4.2 power supply

c ) Input module

The input module has two functions ; reception of an external signal and status display of that
input point . In other words , it receives the peripheral sensing unit's signal and provides
signal conditioning , termination , isolation and / or indication for that signal's state . The
input to an input module is in either a discrete or analogue form . If the input is an ON / OFF
type , such as with a push button or limit switch ,the signal is considered to be of a discrete
nature.if on the other hand , the input varies , such as with temperature pressure , or level , the
signal in nature. Peripheral devices wending signals to input modules that describe external
condition an be switches ( limit , proximity , pressure , or temperature ) push buttons , or
logic , binary coded decimal ( BCT ) or analog to digital ( A / D ) circuits . These input signal
poises are scanned , and their status communicated through the interface module circuitry
within each individual PLC and I/O base 121 Waleed , ( 2009 ) . p . 109 ).
d ) Output module
The output module transmits discrete or analogue signals to activate various devices such as
hydraulic actuators , solenoids , motor starters , and displays the status ( through the use of
LEDs ) of the connected output points . Signal conditioning termination , and Isolation are
also part of the output module's functions . The output module is treated in the same manner
as the input module by the processor ( 121 Waleed , ( 2009 ) . p . 112 ).
e ) Central processing unit ( CPU )
The function of the CPU is to control the operation of memory and I/O devices and to
process data according to the program or in other words , makes decisions and executes
control instructions based on program instructions in memory . It is responsible for reading
inputs . executing the control program , and updating outputs . It is always referred to as the
processor consists of the arithmetic logic unit , timing , program counter , address stack and
instruction register ( 12 ] Waleed , ( 2009 ) . p . 120 ) .
Figure 4.3 Cpu

 Memory
It is the area that holds the operating system and user memory . The operating system is
actually system software that the PLC , ladder diagram , timer and counter values are stored
in the user memory . Depending on users need varies types of memory are available for
choice . Such as RAM ROM , EPROM , and EEPROM . EEPROM ( electrically erasable
programmable read only memory ) combines the access flexibility of RAM and non -
volatility of EPROM in one ( 12 ) Waleed , ( 2009 ) , p . 120 ) .
 Level Sensor
A level sensor detects the level of liquids and other fluids . Substances that flow become
essentially horizontal in their containers ( or other physical boundaries ) because of gravity .
To measure level , two types are possible :
( 1 ) continuous measurement with an integral sensor , or
( 2 ) switching by a point measurement when the sensor comes in contact with the product or
level switch . Capacitance level sensors excel in sensing the presence of a wide variety of
solid, aqueous and organic liquids , and slurries . Capacitive sensor can act as a level switch
or digital sensor . We have this type of two level sensors .
Figure4.4 Water level sensor

 Buzzer
To inform the motors stoppage .
 Switch

There are two fundamental uses for switches . First , switches are used for operator input to
send instructions to the control circuit . The second switch is an emergency switch which is
used to stop the system when there is an emergency case . The most common switch is the
push button. It is also the one that needs the least Description because it is widely used in
automotive and electronic equipment applications ( 3 ) A.Thue , p . 110 ) .
There are two types of push button , the momentary and maintained . The momentary push
button switch is activated when the button is pressed , and deactivated when the button is
released . The deactivation I done using an internal spring . The maintained push button
activates when pressed , but remain activated when it is released . Then to deactivate it , it
must be pressed a second time ( [ 3 ] A.Thu , 111) .
The contacts on switches can be of two types . These are normally open ( NO ) and normally
closed ( NC ) . Whenever a which is in its deactivated position , The NO contacts will be
open ( non - conducting ) and the NC contacts will be closed ( conducting ) .Figure below
shows the schematic symbols for a normally open push button ( left ) and a normally closed
push button ( center )(3) ( A.Thue... , p.112 ).
Figure 4.3 Symbol of start and stop switches.
Contactor Coil ;Coil Characteristics depends on the type of wire and the manner in which it
is wound.
 Contactor
Contactors are relays that switch high current loads . Used as an electrical switching device .
Is used to control an electric load in control systems and Make or break a set of contacts that
control the voltage applied to some load in cooling systems .
Contactor Contacts : The contacts of a contactor make a complete circuit when the
contactor is energized , allowing voltage to flow to the controlled load .

Figure4.7 Contactor
 Motor pump
Motor Pump is used to convert electrical Energy to mechanical that of Pressure in a liquid in
order to move the liquid from a low elevation to a higher elevation or , from a low pressure to
high pressure system . Pumps move liquids , compressors move gases . There are many types
of motor for a purpose of pumping water or other liquid we use three phase AC motor for
implementation of our project . We can control the water pump by connecting it with an
output module of PLC relay circuit . When PLC sends a positive signal ( + 24v ) or a ground
signal ( 0 ) to the motor driver circuit , then the water pump become ON / OFF respectively
( [ 4 ] Ahmed . ( 2008 ) , p . 551 ) .
Figure4.8 Pumping motor [ 1 ]

 Valve
It helps to open and close the water tanks .

Figure1.9 Automatic water valves .

 Timers
The time controlled relay is used in any automatic process where it is necessary to program
the lasting of operation . In our case we use ON delay timers . Is a special kind of relay that
when its coll is energized must wait for a fixed length of time before closing it contact ? The
waiting time is dependent on the " set value " ( SV ) of timer . In this project there are four
timers ( 4)Ahmed , ( 2008 ) .. p . 556 ) .
Figure 4.10 On delay timer

4.9 Block diagram and flow chart of the system
Power Power relay

Source Supply
Contactor
Level Siemen
Sensor Valve
PLC
Switch Motor pump

Buzzer/alam
Figure4.11 Block diagram process.
4.10 Flow chart
This flow chart was translated first into control techniques simulation (EKTS) then into
ladder logic diagram(LD)using STEP-7 Micro/WIN software.
Start
Relay
energized
Above
Below
High NO
Low
Yes Level YES
Level
NO
Sensor Open Sensor open Sensor Closed

Sensor Closed
Valve
Valve2 Closed Valve2 open Valve open
Closed Alarm
Alarm ON Alarm OFF ON 10sc Alarm OFF
10sc
Figure 4.12 Flow Chart of System
Input for PLC

No Input device name Output symbols
1 Stop push button I0.0
2 Start push button I0.1
3 Low level sensor I0.2
4 High level sensor I0.3
Table 4.1 Input device name and symbol

Output for PLC
NO Output device name Output symbols
1 Relay(R) Q0.0
2 Main contactor (KM1) Q0.1
3 Star contactor (KY1) Q0.2
4 Delta contactor (KD1) Q0.3
5 Valve(v1) Q0.4
6 Buzzer1 Q0.5
7 Main contactor(KM2) Q0.6
8 Star contactor(KY2) Q0.7
9 Delta contactor(DK2) Q1.0

10 Valve(V2) Q1.1
11 Buzzer2(Alarm) Q1.2
Table 4.2 out put device name and symbols
Figure 4.13 control and power circuit of system

The project mainly done with PLC software STEP 7-200 Micro/WIN software was used for
designing this project based on PLC.for hard ware simulation ,control ckt system design by
using Electric Control Techniques Simulation (EKTS).The figure above shows .
when we press the Start push button , Power will pass through the Relay coil ( R ) and it
becomes energized , at this time the normally open relay contact ( R ) will closed and it can
latch the circuit after the start push button release .

Figure 4.14 The ladder diagram of the system on PLC software

4.11 Working principle of the system

First of all , the above ladder diagram program is written on step7-200 software by using our
computer . When the operator of the system starts the system by pressing the start push
button the CPU checks the status of the input sensors . Let say the water tank is empty the
status of high level and low level sensor is zero that means the two sensors send zero - volt
digital signal . Then the CPU sends 24 volts to the relay.coil ( R ) and the submersible motor
starts pumping or submersible motor starts working and Star - Delta conversion takes place to
start the pump . At this time since the water is below low level sensor , the alarm will be on
for 10 seconds . Distribution of water is not starting till the water is above low level sensor .
After some time , the water reaches to low level sensor then , the low level sensor sends 24v
signal to CPU then , CPU sends 220v to the distributor motor main contractor ( KM1 ) and it
will have energized . Star - Delta ( KYI - KDI ) conversion takes place to start the distributor
motor then , the water will distribute to the company . However , when the water reaches to
the high level sensor , the high level sensor will send 0v or zero ( 0 ) digital signal to the CPU
then , CPU sends 0v to the submersible motor then , the motor will de - energized or sucking
of water will stopped . At this time , since the water is above the high level sensor , the alarm
will be on for 10seconds . But distributor motor continues its work .
Figure4.15 Simulation result of distributor motor pumping

The figure shown above when the water reaches to high level sensor , the sensor detects
overflow of water and become active , it gives alarm for 10sec so that NO contactor of low
level becomes close then the main contractor ( KMI ) will be energized then distributor motor
pump the water . Automatic valve becomes open , simultaneously Distributor Motor pump
run with Star ( KY1 ) for 10sec and then continues pumping water to the company with Delta
( KDI ) .

Figure 4.16 Simulation result low level operation system of ladder diagram
As shown from the above Ladder diagram the level of water increases and reach to high level
sensor then the high level sensor ( I0.3 ) send ( 1 ) digital signal at the same time the alarm
( Q1.2 ) become active and gives sound to notify the concerned body that the water tank is
full . So the main contactor ( KMI ) Q0.1 . star ( KY1 ) Q0.2 and valve Q0.4 of low level
system become active ( 1 ) . Q0.2 becomes zero and Q0.3 will be ( 1 ) which implies the
distributor pump starts with star ( Q0.2 ) and after 10sec the star becomes out and the pump
continues running with delta ( Q0.3 ) starts with star ( Q0.2 ) and after 10sec the star becomes
out and the pump continues running with delta ( Q0.3 )

Figured.17 Simulation result of submersible motor pumping

As shown from the above figure when water level reaches to low level sensor as a result
distributor motor will not work then the sensor detects and gives alarm so notify the
concerned body however , high level sensor is normally closed and main contactor ( KM2 )
becomes energized then submersible motor gets power . As a result , submersible motor will
start pumping water , first it starts by Star ( KY2 ) energized and after 10sec will changed to
Delta ( KD2 ) energized . Submersible motor Pumping water to the tank continues until the

level of water reaches to high level sensor .
Figure 4.18 Simulation result of low level sensor

As shown from the above Ladder diagram the level of water decrease and reach to low level
sensor then the low level sensor ( 10.2 ) send ( 1 ) digital signal at the same time the buzzer
( Q0.5 ) become active and gives sound to notify the concerned body that the water tank is
low . So the main contactor ( KM2 ) Q0.6 , star ( KY2 ) Q0.7 and valve Q1.1 of high level of
the system become active ( 1 ) . Q0.7 becomes zero and Q1.0 will be ( 1 ) which implies the

submersible Moor pump starts with star ( Q0.7 ) and after 10sec the star becomes out and the
pump continues running with delta ( Q1.0 ).
Figured 4.19 When both motor pumping

When the water above low level sensor , the sensor detects it and become active so the NO
contact becomes close then the distributor motor pump main contactor ( KMI ) will be
energized . Automatic valve becomes open , simultaneously Distributor Motor pump run by
start Star ( KY1 ) for 10sec and then continues pumping water to the company with Delta
( KD1 ) .

Figure 4.20 Simulation result of the overall system

The simulation result shown above figure is status of high level ( I0.3 ) and low level ( I0.2 )
sensor is zero that means the two sensors send zero - volt digital signal . Then the CPU sends
24volt ( 1 ) digital signal to the contact Q0.2 and Q0.7 will be active ( 1 ) for 10sec . After
10sec the adjusted contact Q0.3 and Q1.0 will be active so submersible and distributor motor
pump water from the tank by star motor starting and continues with Delta , simultaneously
the automatic valve(Q1.1) and (Q0.4) will be active ( 1 ) which means it opens to allow

movement of water to the tank but the alarm OFF ( Q0.5 ) and ( Q1.2 ) until either of sensor
is deactivate.
4.13 Cost Break down analysis

The table below shows the cost of our quantity used in our project.
S.NO Component name Quantity Price per

quantity(birr)
1 Contactor 6 468.00
2 Relay 1 56.00
3 Timer 4 392.00
4 Buzzer 2 1,304.00
5 Push button 2 64.00
6 Float sensor 2 128.00
7 Pump motor 2 19,560.00
8 Valve 2 196.00
9 Total 21 22,168.00
Tablet4.3 Cost breakdown analysis

Comment :
If the company implement this project ; It will get great benefit ; previously the motors
working by using direct on line starting method so the motors repeatedly failed and
challenging the company so that ; the company faced to the unnecessary costs.so in order to
overcome this unnecessary costs the star delta starting mechanism will be the preferable one .
Due to it overcome maintenances cost , save power factor credit and save some of the spare
parts from the burning .
4.14 Summary of the project

To summarize this project proposal , if it is accepted , the company will be beneficiary
because it can prevent expenditure of huge cost , increase production speed , minimizes the
number of manual worker , it can also create a safe working area , and others , so it will play
a big role for company's productivity.

4.15 Conclusion
We identify so many problems in the factory ; from this we take the automatic water level
controller and motor stoppage alarm sound due to water is the life for the cable in the
factory . so that our project can solve the problem that faced and challenging the company
repeatedly and continuously . Moreover , the company will be beneficiary if it is installed
since it can prevent expenditure of huge cost , increase production speed , minimizes the
number of manual workers , it can also create a safe working area and prevent the product
scrap , save valuable time for the company . Due to the necessity of our project it can
overcome the wastage of the maintenance time , wastage of natural resources like water and
save some spare parts from the burning ; it is good for the factory to improve and develop its
production abundance , speed , performance and efficiency of the production . So it will play
a great role for the company productivity Generally , we have done classical control
implementation our project and we get good results .
4.16 Recommendation
Based on the necessity of our project we would like to suggest and recommend on the
following points.
 Previously the company uses direct on line ( DOL ) starting mechanism to start the
pumping motor but,the motor failed want repeatedly and challenging the company ; so
that company faced to the necessary costs like maintenance costs , purchasing motor and
purchasing some spare parts therefore , we would like to recommend the company to use
star-delta stating mechanism which increase the life time of the pumping motors.
 The place where the pumping motor and chiller machine installed is not good and
suitable for maintenance and for those who wants to see how the pumping motors and
chiller machine works therefore they should use the suitable and attractive place for the
pumping motor and chiller machine .
 They control the level of the water manually by stopping one and starting the others so
that this one is tiresome consequently , it is good to use level sensors which senses the
level of the water and operate automatically.

 The company checks the failures of the pumping motors physically so that it is better to
use some indicators to indicate the continuity which save valuable time for the company
and overcome the wastage of manual workers .
 We treat the surface and the environment where the chiller machine and the pumping
motors is installed but the company should not clean the dust and other viruses from the
surface of the motor , chiller machine and the environment where it is installed
therefore , these may cause the pumping motor to be rust , fall , loss its performance and
function so that it is better to clean and protect surface of the motors and the environment
where its installed.
 They should have to use prime mover that is good for the treatment of the motors.
 We would like to suggest the company to accept and install this project practically since
it is good for the company which increases the productivity .
 Finally , we would like to recommend those who interns to the company and given the
same project it is better to do by Scandia control to easily overcome the problem that
challenges the company so this one the preferable due to it increase their productivity.

CHAPTER FIVE
CONCLUSION AND RECOMMENDATION
5.1 Recommendation
We have kindly recommended on the following problems seen in the company:
They use half cut method which is a manual work done by stretching back the rolled wire and
results to the wastage of cables. Hence it is recommended to use a fault locater device which
is used to locate the continuity place.
While the packing machine is in use, if the power supply is stopped, then the belt which holds
the rolled coil and rotation also stop working. This can cause burning of all rolled wires exist
on belt due to high temperature. Thus, it is better to use a battery backup device during this
time.
The company should have given me safety materials for protection.
The workers of the company must have been told not to approach machines such as assembly
machine which have high load and have been causing injury.
The company should have assigned engineers on each section to enable me get detail
information about working principle of machines, and allowed me participate every day per
week.

5.2 Conclusion
EL-SEWEDY CABLES ETHIOPIA PLC found in dukem is manufacturing low voltage, control
and overhead transmission cables. The company has three production sections i.e. metal, low
voltage and maintenance, and its own quality control to check the quality of cables. we was
practicing in this company for four months. During my practice, we have seen how the cables are
drawn, stranded, insulated and sheathed. Challenges and problems are identified, and the project
is designed to overcome these challenges and solve the problems. we have also tried to
understand work flow of machines when they are operating, being installed and maintained by
technicians. Generally, the internship program applied in EL-SEWEDY CABLES ETHIOPIA
PLC helped me to improve practical and theoretical skill, enhance interpersonal communication,
develop team playing skill, gain leadership skill, understand about work ethics and related issues,
and improve entrepreneurship skill.
References
[1] Website: www.el-sewedy_cables.com
[2] Waleed, Tamer (2009). Elsewedy cables manuals
[3] William A. Thue. Electrical Power Cable Engineering, Third Edition
[4] Ahmed Elsewedy (2008). Power Cable Catalogues

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DIRE DAWA UNIVERSITY

FACULTY OF ELECTRICAL ENGINEERING

DEPARTMENT OF ELECTRICAL AND COMPUTER ENGINEERING

HOSTING COMPANY: ELSEWEDY CABLES FACTORY

Duration of Internship stay: JUL, 01/10/2024 G.C- SEMP, 8/02/2024G.C

Mentor Name: Mr. DAWI.A (MSc.)

Submission Date: 20/09/2024

Dire Dawa institute of technology school of ECE Power stream

Name of Academic Advisor: Mr Dawit.A..................Signature............Date............

Dire Dawa institute of technology school of ECE Power stream

Dire Dawa institute of technology school of ECE Power stream

Dire Dawa institute of technology school of ECE Power stream

3.2 enhancing interpersonal communication.................................................................................xliii

Dire Dawa institute of technology school of ECE Power stream

Dire Dawa institute of technology school of ECE Power stream

BACKGROUND OF EL-SEWEDY CABLES ETHIOPIA PLC

1.1 Brief history of company

1.2. Mission, vision and value of the company

Dire Dawa institute of technology school of ECE Power stream

transmission lines manufacturing sector through providing superior quality cables

1.2.3. Core values

 Integrity and trust

1.3. Main products

1.3.1. Low voltage cables

Dire Dawa institute of technology school of ECE Power stream

Dire Dawa institute of technology school of ECE Power stream

Dire Dawa institute of technology school of ECE Power stream

Dire Dawa institute of technology school of ECE Power stream

Dire Dawa institute of technology school of ECE Power stream

Dire Dawa institute of technology school of ECE Power stream

1.3.2. Overhead transmission line cables

Figure 1.17 All Aluminum conductors (A.A.C)

Figure 1.18 Aluminum conductor steel reinforced (A.C.S.R)

Figure 1.19 Bare Soft and Hard Drawn Copper Stranded

 Plain bare hard drawn Copper conductors as per DIN 48201

Dire Dawa institute of technology school of ECE Power stream

Aluminum Conductors & XLPE Insulated

Figure 1.20 Aluminum Conductors & XLPE Insulated

1.3.3. Control cables

Figure 1.21 Solid copper conductors, PVC insulation, PVC sheathed

Dire Dawa institute of technology school of ECE Power stream

1.4. Main customers of the company

 Power engineering (midroc plc.)

 Sigma electric plc.

 Dama trading plc.

 Sunshine construction plc.

Dire Dawa institute of technology school of ECE Power stream

 Ethio crown cork plc

 ZF building and electrical mater plc

1.5. Over all organization and work flow of the company

H.R Factory Finance

q.a$i Qualit Testin local foregion accou costi Coils S$m

Dire Dawa institute of technology school of ECE Power stream

Low volt Carpentry Metal Machining

OVERALL INTERNSHIP EXPERIENCE

2.1 How we get into the company

2.2 Sections in the company

2.2.1 Metal section

2. Stranding section: the area at which stranding process carried out

 Aluminum /Al/ with Diameter 9mm and weight 1.5 ton