Tayache

DEBRE TABOR UNIVERSITY FACULTY OF TECHNOLOGY
DEPARTMENT OF ELECTRICAL AND COMPUTER
ENGINEERING (POWER STREAM)
HOSTING COMPANY: DASHEN BREWERY SHARE COMPANY
INTERNSHIP REPORT AND PROJECT
Prepared By:
1. ALEMINEW ALAMIREW.………………………………………116/11
2. ELIAS WUBET…………………………………………………367/11
3. SEDEKU SHIETIE……………………………………………...964/11
4. TAYACHEW TAKILO………………………………………..1010/11
Submission Date: 29/06/2015 E.C

Debre Tabor, Ethiopia
INTERSHIP REPORT AND PROJECT IN DASHEN BREWERY SHARE COMPANY
DECLARATION
We declare that, this internship report on Dashen brewery share company is our original work
done by our full effort and exclusively suggestion of our mentor and company supervisors. We
would like to make sure the report is accompanied by us by referring different references and by
asking electricians in the company.
Student Name: Signature Date
1. _________________ ________
______
2._________________ ________ ______
3._________________ ________
______
4._________________ ________
______
Advisors Name: Signature Date
_______________________ _______ ______
________________________ _______ ______
Chairman Name
_________________________ ________ _______
Department Head Name
__________________________ _______ _______
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DEBRE TABOR UNIVERSITY 2015 E.C
ACKNOWLEDGMENT
Firstly, we would like a great thanks to God for his willing and giving strength to finish this
internship report and secondly, we would like to thank Dashen Brewery Share Company for
giving us the opportunity to work in the company. We are also heartily gratitude to our EIAMD
supervisors Mr.Abera and Mr.Derso who gave us more knowledge about electrical instruments,
control systems and about electrical power installation system in the industry plant. Also, great
full tanks to all members of employers in the company for their contribution in knowledge and
social life skills. Likewise, we would like to express the deepest gratitude for our advisors
Mr.Honelign.D and Mr.Chalachew.A who advises us to do this internship report by attending our
progress friendly. Lastly, we would like to thank our university who engaged us in internship
program to get practical skills.
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EXECUTE SUMMARY
Internship program has a key role for us to have an experience on practical skills by interrelating
our previous theoretical knowledge’s and helps to apply hands on work duty in a certain
occupational field. With this concept we have been working in Dashen Brewery Share Company
from October 01/2022 up to January 30/2023 G.C. During this period, we have been working in
the three sections (beer processing, production and utility) so as to have deep knowledge in
process of beer production. Among those sections we were involved mostly in production section
since most of the electrical system components, their maintenance, and control system of
different machines is available in this section. This report consists chapters including brief
history of the company, its vision, mission and objectives, its organizational structure, production
process of the company, overall internship experiences in different electrical system components,
electric power distribution, control system in PLC, overall internship benefits we gained, overall
achievements and after we have given recommendations and conclusions for our discussions. On
the other hand, we developed our social and communication skills, developed how to
communicate with different class of employees (how to communicate with an engineer, operator
and technicians also developed our work with ethics like punctuality, working with others (team
work).
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TABLE OF CONTENTS
DECLARATION........................................................................................................i
ACKNOWLEDGMENT............................................................................................i
EXECUTE SUMMARY...........................................................................................ii
LIST OF FIGURES..................................................................................................vi
LIST OF TABLES.................................................................................................viii
CHAPTER ONE........................................................................................................1
1. INTRODUCTION.................................................................................................1
1.1 Background of Dashen Brewery Share Company......................................................1
1.2 Main Customers and End Users of the Company......................................................2
1.3 Vision, Mission and Objective of the Company............................................................3
1.3.1 Vision..............................................................................................................................3
1.3.2 Mission............................................................................................................................3
1.3.3 Objective of the Company...............................................................................................3
1.4 Organizational Structure of the Company..................................................................4
1.5 Key Stake Holders of Dashen Brewery Factory........................................................4
1.6 Production Process of the Company..........................................................................5
CHAPTER TWO.......................................................................................................6
2. OVERALL INTERNSHIP EXPERIENCE...........................................................6
2.1 Objectives of the Internship.......................................................................................6
2.1.1 General objective:............................................................................................................6
2.1.2 Specific internship objectives..........................................................................................6
2.2 How We Did get the Dashen Brewery Share Company............................................6
2.3. Work Section.............................................................................................................7
2.3.1 Utility section..................................................................................................................7
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2.3.2 Beer processing section...................................................................................................7

2.3.3 Bottling section................................................................................................................7
2.4 Overall System Components Found in Dashen Brewery Share Company..............20
2.4.1 Programmable logic controller (Plc):............................................................................20
2.4.2 Components of plc.........................................................................................................21
2.4.3 Operation principle of plc..............................................................................................23
2.5 Input Devices:...........................................................................................................23
2.6 Output Devices.........................................................................................................27
2.6.1 Drive motors..................................................................................................................27
2.6.1.1 Synchronous motor.....................................................................................................27
2.6.1.2 Induction motor..........................................................................................................27
2.6.1.3 Servo motor................................................................................................................28
2.6.2 Relay..............................................................................................................................28
2.6.3 Contactor.......................................................................................................................28
2.6.4 Solenoid valve...............................................................................................................29
2.7 Electric Power Distribution......................................................................................29
2.8 Major Duties of the Intern........................................................................................31
2.9 Challenge Faced and Measures Taken.....................................................................31
2.9.1 The challenge we faced.................................................................................................31
2.9.2 The measures we have taken.........................................................................................32
CHAPTER THREE.................................................................................................33
3. OVERALL BENEFITS THAT WE GAINED FROM THE INTERNSHIP......33
3.1 Theoretical and Practical Skill.................................................................................33
3.2. Improving Team Playing Skills...............................................................................34
3.3 Interpersonal Skills...................................................................................................34
3.4 Improving Leadership Skills....................................................................................34
CHAPTER FOUR...................................................................................................35
4. IDENTIFED PROBLEMS AND SOLUTIONS PROPOSED............................35
4.1 Identified Problems..................................................................................................35
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4.2 Solution Proposed.....................................................................................................35

4.3 Abstract....................................................................................................................35
4.4 Introduction..............................................................................................................36
4.4.1 Background of study.....................................................................................................36
4.5 Statement of the Problem.........................................................................................36
4.6 Objectives of the Study............................................................................................37
4.6.1 General objective...........................................................................................................37
4.6.2 Specific objectives.........................................................................................................37
4.7 Significance of the Study.........................................................................................37
4.8 Scope of the Project..................................................................................................37
4.9 Literature Review.....................................................................................................38
4.10 Methodology..........................................................................................................39
4.10.1 Procedure of the study.................................................................................................39
4.10.2 Project methodology....................................................................................................40
4.11 Block Diagram Description....................................................................................40
4.11.1 Operation of stepper motor:........................................................................................43
4.11.2 Location of tapping.....................................................................................................44
4.11.3 Operation of tap changing...........................................................................................45
4.11.4 System design and analysis.........................................................................................46
4.11.5 Overall system flow chart............................................................................................50
4.12 Result Analysis and Discussion.............................................................................51
4.12.1 Overall circuit diagram of system...............................................................................52
4.13 Conclusion and Recommendation..........................................................................55
4.13.1 Conclusion...................................................................................................................55
4.13.2 Recommendation.........................................................................................................56
CHAPTER FIVE.....................................................................................................57
5. CONCLUSION AND RECOMMENDATION..................................................57
5.1 Conclusion................................................................................................................57
5.2 Recommendation for Dashen Brewery Share Company..........................................57
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5.3 Recommendation for University..............................................................................58

REFERENCE..........................................................................................................59
LIST OF FIGURES
Figure 1.1 : Background of Dashen brewery share company........................................................................2
Figure 1. 2: Organizational structure of Dashen brewery..............................................................................4
Figure 1. 3: Block diagram of Overall Production process of the company..................................................5
Figure 2. 1: Overall flows of the product in the packaging room..................................................................8
Figure 2. 2: Depallatizer machine..................................................................................................................9
Figure 2. 3: Uncaser machine......................................................................................................................11
Figure 2. 4: crate washer machine...............................................................................................................11
Figure 2. 5: bottle washer.............................................................................................................................12
Figure 2. 6: filler machine............................................................................................................................15
Figure 2. 7: pasteurizer machine..................................................................................................................16
Figure 2. 8: Labeler machine.......................................................................................................................17
Figure 2. 9: Caser machine..........................................................................................................................18
Figure 2. 10: Palletizing Machine................................................................................................................19
Figure 2. 11: Keg machine...........................................................................................................................20
Figure 2. 12: Major components of Programmable logic controller (PLC)................................................21
Figure 2. 13: Input interface module............................................................................................................22
Figure 2. 14: Output interface module.........................................................................................................22
Figure 2. 15: Operation cycles of PLC........................................................................................................23
Figure 2. 16: Contactor................................................................................................................................29
Figure 2. 17: block diagram of power consumption for Dashen brewery...................................................30
Figure 4. 1: Methodology flow chart...........................................................................................................39
Figure 4. 2: Block diagram of the system....................................................................................................40
Figure 4. 3: power transformer....................................................................................................................40
Figure 4. 4: Circuit diagram and waveform for bridge rectifier..................................................................41
Figure 4. 6: LCD..........................................................................................................................................42
Figure 4. 7: Stepper motor circuit diagram..................................................................................................43
Figure 4. 8: operation of stepper motor.......................................................................................................43
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Figure 4. 9: Tap changer location................................................................................................................45

Figure 4. 10: Block diagram for OLTC power and control scheme............................................................46
Figure 4. 11: Tap selection process..............................................................................................................50
Figure 4. 13: Flow chart of overall tap changing system.............................................................................51
Figure 4. 14: System circuit design..............................................................................................................52
Figure 4. 15: Arduino microcontroller stepper motor based automatic tap changer for tap-five................53
Figure 4. 16: Arduino microcontroller stepper motor based automatic tap changer for tap-four................53
Figure 4. 17: Arduino microcontroller stepper motor based automatic tap changer for tap-three..............54
Figure 4. 18: Arduino microcontroller stepper motor based automatic tap changer for tap-two................54
Figure 4. 19: Arduino microcontroller stepper motor based automatic tap changer for tap-one.................55
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LIST OF TABLES
Table 1.1: The basic difference of draught (draft), bottled beer....................................................................2
Table 4.1: showing arrangement of taps with voltage limit.........................................................................48
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LIST OF ABBREVIATIONS
AC Alternating current
BBT Bright beer tank
CPU Central processing unit
DC Direct current
DETC De-energized tap changer
EEPCO Ethiopian electric power corporation
EIAMD Electrical instrumentation and automation maintenance
division
I/O Input output
I/P Current to pressure
KIOT kombulcha institute of technology
LED Light emitting diode
OLTC On load tap changer
PLC Programmable logic control
PTC Positive temperature coefficient
SCR Silicon controlled rectifier
UIL University industry link
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CHAPTER ONE
1. INTRODUCTION
1.1 Background of Dashen Brewery Share Company
Dashen brewery was established at the historical town of Gondar and started to supply its
products on June 2000GC with the total out lay of birr 350 million at the early start-up time, it is
owned by the Amhara national region rehabilitation or development organization. It's named
after Mount Dashen, (Ethiopia's highest mountain elevation 4620 meters), and a
home to rare endemic fauna and flora and renewed for its breath-taking scenery. It
has a production capacity of 300000 hectoliters per annum (151 million bottles), which
expands to 750,000 hectoliters per annum (91 million bottles) with additional investment of birr
110 million which sums up its total investment cost of over birr 460 million birr. Dashen is the
modern plant, occupying an area of 8.5 hectare with building area of 1.2 hectare, which is
annually visited by more than 95,000 tourists. The principal aims of Dashen Brewery Factory is
meeting customer requirement for quality beer and to offer consumers choice in the market by
supplying bottle & draught beer. The brewery has now 510 permanent &contract employees, out
of which 406 are permanent and 104 are contract employees respectively with sexual ratio of
73%male and 27%female. In addition, the Brewery also creates job opportunities for 350 daily
labor workers. Dashen Brewery, the youngest beer factory in the country, is going to plant the
second brewery in the central part of Ethiopia around Debre Birhan town, North Shoa Zone of
Amhara Region, 130Km northeast of Addis Ababa. The ten-year-old brewery, located in the
historical town of Gondar, 748 km north of Addis Ababa. has submitted a request for 20 hectares
of land with a project proposal sent to the Debre Birhan City Administration in December 2011.
Dashen’s administrators plan to build their second beer production center because they believe
the area has a huge potential in the beer market. It will be the second brewery in Debre Birhan,
joining Habesha Brewery Share Company which has already sent a similar proposal to the city
administration. Dashen brewery company power supply is 15 kV gained directly from high
transmission power lines of EEPCO substation.
The main products/ service of Dashen Brewery
 Dashen beer
 Draught beer (locally called Draft beer)
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 Royal beer, unfiltered beer, which is not considered as main product. The Basic difference
between draft and bottled beer: Draft beer is the most popular when available. It is poured from a
tap to serve, and this gives it a unique “mouthfeel” because of the carbon dioxide. Draft beer has
a shorter shelf life than bottled beer because it has not undergone pasteurization before being
packaged into metal kegs. Bottled beer usually, but not always, undergoes pasteurization before
glass bottling and has a shelf life of around six months? For more clarification the table below
illustrates basic difference between draft and bottled beer.
Table 1.1: The basic difference of draught (draft), bottled beer.
Basic Property Draught beer Bottled beer
Pasteurization temperature 73℃ for 30 seconds 27℃ -66℃ for one hour
Number of machinery and Small Large
space requirement
Length of time for expiration About one month About six months
End product container Short cylinder Bottle
Basic beer difference After filtration called bright After filtration called bright
beer beer
Alcoholic content 4.8% 4.8%
Figure 1.1 : Background of Dashen brewery share company
1.2 Main Customers and End Users of the Company

The end users or customers are every person aged above 18 years old. There is no any limit or
boundary in order to be a customer for dashen beer. But it is not allowed to drink for persons
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below 18 years old. The products are distributed across the country in four regions and three
warehouses. The regions are:
 Region 1: covers Amhara, Benishangul and Afar region
 Region 2: covers the whole Tigray region
 Region 3: covers central and west part of Ethiopia
 Region 4: east and south part of Ethiopia
There are three ware houses those are: - Gondar, Addis Ababa, and Woldia. Dashen brewery
exports its products to the following countries. i.e California, Chicago in America, Australia,
Israel, Southern Sudan.
N.B Agent distributes 90% of the product and 10% distribution done by direct distribution to
retailers.
1.3 Vision, Mission and Objective of the Company
1.3.1 Vision
 To make Dashen the central value for quality beer celebrities.
 To build the brands that people love prefer to drink.
 To expand its distribution capacity to many countries.
1.3.2 Mission
 It is an endowment (gift) fund established to contribute for the development of Amhara
region by producing and selling customer proffered or contribute quality beer at
competitive price and generate responsibility.
 To be best Ethiopian beer lead drinks company with sustained revenue growth and
consistently improving returns on invested capital.
 Employees of the brewery have a fair commitment ownership feeling or especially the
technical team their commitment is increasing. Generally, employees in production
quality maintenance department are highly committed energetic with fair a composing.
1.3.3 Objective of the Company
 To support the socio-economic development of the Amhara Region in Particular and the
overall development wellbeing of the country in general.
 Dashen brewery has customer focused orientation and prevalence of accountability.
 Determination of safety stock and recording level and implementation.
 Dashen brewery has well trained and committed work force.
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 It gives value for the eco-environment friendly manner.

 To involve in export market.
 To ensure product consistency at the required level.
 To train all employees of the brewery is to the end of the next year.
1.4 Organizational Structure of the Company
Figure 1. 2: Organizational structure of Dashen brewery.
1.5 Key Stake Holders of Dashen Brewery Factory
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Dashen brewery Share Company is owned by the Amhara National Region Rehabilitation
/Development organization and German’s share (recently shared 49% of it).
1.6 Production Process of the Company
Figure 1. 3: Block diagram of Overall Production process of the company
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CHAPTER TWO
2. OVERALL INTERNSHIP EXPERIENCE
2.1 Objectives of the Internship
2.1.1 General objective:
The main objective of the internship was to gain an experienced practical knowledge in different
electrical equipment’s and control automation systems by inter-relating with the theoretical
knowledge and to upgrade our technology. Internships will provide us the opportunity to test
their interest in a particular career before permanent commitments are made. In general, an
internship is thought of as a program which "narrows the gap" between the academic
environment and a future work environment. Many employers prefer students who have previous
work experience and the Internship provides to have those experiences. Students that participate
in an internship program are generally more confident and more qualified when seeking in the
future employment.
2.1.2 Specific internship objectives
 Internship programs will help to develop problem solving skills.
 To provide intensive field experience allowing for hands-on computer work.
 To know the background of an organization within the Information Systems industry and
to gain a better understanding of its design and structure.
 To develop an understanding of an organization's various management and technical
skills, the communications techniques and the decision-making processes.
 To apply what was learned during coursework (theory, skill development,
professionalism) to the working world.
 To help the student make better Information Systems career choices in the future.
 To allow the student to prepare for their future non-Internship job by seeking potential
places of employment, practicing resume and cover letter preparation, gaining
references, and interviewing if applicable.
2.2 How We Did get the Dashen Brewery Share Company
When we were first arrived in the Dashen brewery share company on February 15/2017, we
reported the letter that was given from university linkage (UIL) office to the company human
resource management personnel. They accept and encourage us to involve in all tasks to make
the internship program more practical and successful. Then we met one of the foremen’s of
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EIAMD head, Mr. Abera, and he understood us why and for what purpose we got him. He told
us how much he and his members were busy to serve their company careers. Despite this he
promised us to help in every aspect during our entire duration of time in the company by
assigning electricians so as to get an experience and practical skills in the electrical system.
2.3. Work Section
The section we have been working Dashen brewery factory comprises or includes three sections:
 Utility section
 Beer processing section and
 Packaging section
Among from those sections, we have been working mainly in Utility Section, because it
involves the Electrical Instrumentation, Automation, and Maintenance Department (EIAMD)
section. In this section there are so many activities which concern more of electrical and
computer engineering, such as:
 Maintenance of production equipment’s and machineries
 Control of production engineering activities and all over power system control
 Maintain and ensure calibration of inspection, measuring, and testing equipment’
We were also involved in bottling and beer processing
2.3.1 Utility section
It is the backbone of the company. Because, it is the sources of power supply, air compressor,
steam, process water, glycol and purified carbon dioxide those have significant impact on
production. Utility section comprises many plants. That is why, it is known as the backbone of
the factory and gives all necessary electric power supply to each section.
2.3.2 Beer processing section
In brew house malt from raw materials stock entered in to mill star. The type of mill star is white
mill. The entered malt milled by roller with the help of warm water. Then the crashed malt is
transferred to mash tun. Then wort is fermented after this the wort is filtered and finally goes to
bottling (packaging) section.
2.3.3 Bottling section
The machines used in the bottling section to fill bottles by beer and to send it to the customers
are: de-palletizer, UN caser, Crate Washer, Bottle washer, Visual inspection screen, Empty bottle
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inspector (EBI), Filler, Pasteurizer, Labeler, Full bottle inspector, Ink jet printer, Caser and
palletizer. The overall process in the production room is as shown below.
Figure 2. 1: Overall flows of the product in the packaging room
De palletizer: It is the process of loading individual crates with bottles from customers to
the conveyor that is goes into the UN caser machine. It is replaced by robotic machine
recently rather than using human power to save money, time and to increase productivity
without any tired.
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Figure 2. 2: Depallatizer machine.
It is controlled by electrical device such as;

 Servo motor: is used to drive horizontal and vertical movements of robotic machine.
 Inductive sensor (buck up switch): - used for the safety of gripper.
 Photo cell: used to indicate the presence of crate and determine distance between bottle and
gripper.
 Encoder: control the movement of the gripper.
 Solenoid valve: hold and release the gripper Camera: used to check if there are 10 crates hold
on the grippers. Photo electric sensor, or photo eye, is a device used to detect the distance,
absence, or presence of an object by using a light transmitter, often infrared, and a photoelectric
receiver. There are three different functional types: opposed (through beam), retro reflective, and
proximity A sensing (diffused). They convert light energy to electrical energy and output signal
to PLC they supply 24v.
 Limit switch: It fixed the movement x-axis and y-axis motion.
UN caser machine: is used to separate empty bottle with crate. Empty bottles are lifted from
the crate by gripper head and set down at predetermine place. It uses pneumatic system to pick
up the bottles. It has 6 gripper magazines. each gripper magazines have 24 gripper heads. each
gripper head has spring and solenoid valve. At the time of squeezing and releasing the bottles the
PLC orders 24v or 0v to be applied to solenoid valve to energize or de energize it respectively.
When the solenoid valve is energized, it makes the plunger inside valve to be opened. At this
time air force with the pressure of 4-6 bar is applied which is greater than the reactive spring
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force and the gripper head squeeze the bottles. When the solenoid valve is de energized the
plunger inside the valve will be closed and the spring force is greater than that of the air force.at
this time the bottles released from the gripper head to the conveyor. There are three photocells
located two at the end parts and one at the middle. The two photocells check the availability of
free crate place and bottle place separately. Here when the conveyor is full of bottles/crates the
photo cell becomes covered by the bottle/crates & receivers cannot get a light from the light
emitter, which means that the conveyor is full of bottles/crates. Then the machine automatically
stops operation & when the receivers get light from the light emitter it will restart automatically.
The middle photocell checks the presence of crates. There are also two internal photocells at end
parts. The first photocell used to detect incomplete crates by its reflector in front of it. The photo
electric reflector is arranged in such a way that the last crate (the six one) can cover it & the
reflector cannot get the light from the photo cell which means the six crates are inserted. If there
are less than six crates it will stop operation. But we can restart manually to operate with less
than 6 crates. The second photocell which is arranged near the first photocell is used to detect too
many crates (greater than 6 crates). During this time PLC sends signal to discharge stopper to
stop crates. There are also 4 photocells (2 senders and 2 receivers) communicated by their own
address to tell the robotic gripper heads are at correct position. There are two capacitive type
proximity sensors to detect the up (sensed by first sensor) and down (sensed by the second
sensor) movement of the centering frame. In this robotic machine three encoders are available,
that are used as input devices for PLC. The first encoder controls horizontal movement, the
second encoder controls the vertical movement of the robotic machine. The last encoder controls
the mechanical pistons that blocks and discharges the crates. The horizontal and vertical
movements are driven by two servomotors separately. There is a counter on the PLC which
counts how many bottles can the machine works per hour & it displays on the screen. Limit
switch fixed the movement x and y-axis motion. A limit switch is an electromechanical device
that consists of an actuator mechanically linked to a set of contacts.
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Figure 2. 3: Uncaser machine.
Crate washer machine: This machine is used to wash crates by using water to clean the crate.
This is done by using water and applying high pressure spray from different direction and finally
the washed crate become inverted upside down for removing broken glass and unwanted craps.
There are motor & other sensors from here. The motor used for deriving the conveyer belt. The
proximity switches sensor used for checking the crates are present or absent.
Figure 2. 4: crate washer machine.
Bottle washer: The bottles that come from Uncases machine through conveyor belt are washed
at this machine stages by caustic and water. In this machine the proper level of caustic soda is
electrically detected by using conductivity meter (sensor). The controls mechanism of bottle
washer is held by the following electrical devices:
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 Photo cell: it is used to detect whether there is broken or short bottle. It also identifies if the
bottle is not in its exact position. The bottles enter to washer machine firstly, checks by two long
photo cells enter correctly or not, and unwanted materials enter. This photo cell perform action
by sending light and the other one receives the light if, unwanted material enter block the light
comes from the sender photo cell then the receiver photo cell send message to PLC. The PLC
send signals to bottle washer automatically stop. The left two short photo cell counts the bottles
enter in the form of pulse continuously and display on the display board.
 Encoder: it synchronizes the motion of motors and also use to count the number of bottles on
the washer.
 Temperature sensor: it detects the temperature of the washing water.
 Manometric switch: identifies the pressure of the incoming water.
 Driving motors: they derive the gears that rotate the washer machine. In bottle washer 11
electrical drives are available from those 7 motors work synchronously by using electrical
encoders that used for synchronization to move the bottle holder chain with the same speed and
frequency. The second up to eighth are synchronous motors to wash bottles at equal time
interval. These motors are coupled with 9 encoders at each drive. The other two motors are big
11.5 KW motors used to adjust two caustic levels. The first and the last motors are driven
asynchronously because their function is to bring and out bottles respectively.
 IP positioner: It checks the amount of steam.
Figure 2. 5: bottle washer.
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Visual inspection screen: It is used to identify dirty, unwashed, forging (other bottles which is
not Dashen beer bottle) and broken bottles manually. Here error can be occurred, since it is
manual operation.
Empty bottle inspector: It is used to inspect the empty bottles before it goes to filler and
cause unwanted bottles dragged to another conveyor path. The following parameters of the bottle
are checked:
Optical (mechanical) gap detection: stops the machine if there are fallen bottles or gaps in
bottle flow.
Optical detection of too high or short bottles: Faulty bottles are rejected by a pusher
installed at the in fed.
Contour detection: detection of bottle shapes and bottles whose shape is substantially
different from the normal production bottle.
Glass color detection: detection of bottles which substantially deviate from production bottle
with regard to color or color intensity. Light emitter bottle receiver evaluation
color of the bottle
Base inspection camera technology: a stroboscope lamp illuminates the bottle from below.
Alight meter in the camera sends signal to the control unit which automatically adjusts the
exposure time of the camera the light transmission ratio of the bottle material. The camera takes
an image of the bottle base and converts the signal into digital image data. The digitalized image
data are passed on via the control unit to the individual evaluation unit (256 gray scale
increments) and are displayed on color monitor. As soon as pre-set threshold values are exceeded
a signal is sent to the rejection unit. A clock pulse generator coordinates camera, light controller
&evaluation unit.
Neck finish inspection, camera technology: it is illuminated from above by a dome – type
LED array. The camera takes an image of the bottle neck finish and converts the signal to digital
image data. The digitized image data are passed on via the control unit to the individual
evaluation unit (256 gray scale increments) and are displayed on color monitor. As soon as pre-
set threshold values are exceeded a signal is sent to the rejection unit. A clock pulse generator
coordinates camera, light controller &evaluation unit.
High frequency caustic detection: the bottle passes the high frequency transmitter the
antenna integrating the high frequency receiver. Measures the electronic conductance of the
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various media. The signals are passed to the evaluation unit if the value measured exceeds the set
limit value a fault is registered, the rejection unit is activated. Finally pure bottles sent to filler
and un-cleaned bottles returned back to bottle washer.
Glide liner: It is a device which located before filler machine and labeler machine the
applications of this device is to guide the bottles that come in many lines into a single line. This
is done by varying the speed of conveyors. This device is a microcontroller that adjusts the bottle
spacing and other parameters that the filler machine needs before the bottles are entered to the
filler machine. Photo cell: detect the presence and absence of bottles. Proximity sensors: This
device is a microcontroller that adjusts the bottle spacing and other parameters that the filler
machine needs before the bottles are entered to the filler machine.
Crower filler and machine: This is mechanical filling machine in order to fill empty bottles
by beer. The filler machine can fill up to 42,000 bottles in one hour if it works without any
failure.
Packing: whenever the motor starts working the magnet turned on. The dc motor will start
picking the corks and then these corks transferred into the filling and packing machine. The
packing machine is made to precisely fit with the size of the cork if the cork is not in its proper
position the machine will adjust in its proper size. In this machine there are 3 proximity sensors.
The first one checks the presence of bottles that is ready to pressurizing one. The second
proximity sensor is located on before beer filling that checks broken bottles and the 3rd one
check to refuse the entry of broken bottles. In addition to this there are also in feed monitor and
encoder. The in-feed monitors are photo cells that control the position of bottles at the in-feed
part and the encoder is used to control the movement of the bowl. Electrical components in filler
machine are: -
 Solenoid valve: It controls the flow of beer by closing and opening the valve, which is derived
(energized) Principle and operation of solenoid valve. A solenoid valve is electromechanical
operated valve.
 IP positioner: check the concentration set point of carbon dioxide (co2) in the bottle.
 Slip transmitter: is a conductor cable connected to the solenoid valve.it rotates the coil inside
the solenoid valve to suck or out the air.
 Level sensor: it detects upper and lower filled of the bottles.
 Pressure sensor: it senses tap at bottom and top of the bottle.
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 Motor drive: they derive the gears that rotate the filler machine.
 Incremental encoder: device used for speed control purpose in the filler machine.
Figure 2. 6: filler machine
Pasteurizer machine: Pasteurization is the process of killing organisms. The pasteurizer

machine with elevated levels of heat will kill organisms, heat beer to arrest biological
contamination, destroy viability of yeast and prevent post fermentation. The beer is pasteurized
at the temperature of 66℃ , but this temperature is reached progressively (i.e 24.7 ℃ , 44℃ , 54
℃ , 66℃ ) and decrease gradually to 24.7℃ before finishes the pasteurization process. The total
time taken from pre-pasteurization period to cool dawn stage is about 60 minutes. This machine
is controlled by different types of electrical equipment, such as:
 PID controller: controls (adjusts) the hot and cold-water valves, pump pressurizes the water.
 Temperature sensor: controls the temperature of the water by sending 4-20 ma signal to
PLC and the PLC process it and sends out current signal to I/p positioner and the I/p positioner
changes it to pressure signal to adjust the heat exchanger. When the Temperature is above 66 ℃ ,
the system derivate by the PLC system and then the valve is opened and the steam is out and the
air is inlet to the system. Generally, if temperature sensor detects low or high temperature at one
of the pasteurizing stage PLC orders I/P positioner to open and add steam or water respectively.
I/P positioner is a solenoid single act positioner that use to open and close the valve it converts
an electronic input signal (typically 4-20ma) to pneumatic output signal 6bar or 90 psi depending
on the control pressure. This air is supplied from utility section about 6 bars. this air is used to
push the diaphragm of I/P positioner to open the valve.
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 Manometric switch: is used to measure the pressure of water and control the motor which
pump the water. If the actual pressure of water in the pump is below the set point it makes stop
the pump motor by opening the circuit. It is also called motor dryer protector. i.e when the level
of water bath is empty, it stops the pump motor.
 Induction motors: used to run the pump motors at constant speed, no frequency convertor for
these motors.
 Pressure transmitter: which is used to measure level of water in the bath in milliliter. It
changes this value to 4-20 mA signal and sends to PLC, the PLC sends signal to regulator value
to make it on/off.
Figure 2. 7: pasteurizer machine
Labeler machine: The main function of labeler is labeling on neck and body of the beer bottle
to differentiate the factory products among others by stamping its own trade mark (Dashen beer)
which is body and neck labels. The appearance of the bottle is extremely depending on the
quality of the labeling. To be able to do this; label paper must have the following properties.
 Amount (volume)
 Expired date
 Production date and
 Ingredients (food grades)
 Stamp the brand at the body and neck.
 The main operation labeler making label marker. This machine works with different sensors
and encoders to control the overall functionality of labelling process. There are two proximity
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sensors, two photocells, counter, encoder and different derive motors. The first proximity sensor
that is located at the in-feed part checks the gap and positions of bottles, the second one checks
the presence of crown and the two photocells used to check body and neck label of a bottle. The
counter is used to count the normal, under fill and over fill bottles that are displayed on the
control panel touch screen. The encoder that is located on the bottom of the machine which is
used to tell unwanted bottle reached to the pusher. The labelling process is performed by the help
of the glue (‘which is heated by glue heater at 35°C) and lubricates the worm & gear for the
sticking purpose during stamping of labels on the bottle the labels are given as an input to the
bottle by the help of high pressure. The labeler has maximum labelling capacity of 48,000 bottles
per hour.
Figure 2. 8: Labeler machine
Full bottle inspector machine: This machine located after labeler machine that controls the
quantity of the beer that reaches the customer and checks the following parameters: crown and
uncrown corks, under filled and over filled bottles, whether the two papers on the neck and body
present having the trade mark (i.e dashen beer) of the company attached to the to the filled
bottles or not. The above parameters are checked with different types of sensors. The crowned
and uncrowned bottles are checked by inductive sensor which is capable of sensing metals. This
sensor send ray to crown corks at the neck of bottles and compare the detected information after
receiving the reflected ray to the pre-set information. All the above parameters are done in the
same fashion. If one of the above parameters are not satisfied the beer bottle will be pushed by
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mechanical pusher (rejection unit). i.e it will not go to the next stage (caser machine). This
pusher is solenoid act unit. Pusher reject bottles by air when the solenoid become energize since
it attracts the metal closing the air valve of pusher due to electromagnetic field creation. All
sensors are located to their working area. This means crown cork sensor placed at the top or neck
of bottles. The FBI operation system is radioactive system which is used to identify the over &
under fill beer.
Ink Jet Printer: It is an ink jet printer type which helps to print production date on the bottles.
This machine has an interrupted power supply to operate the machine fast.
Caser machine: This machine is used to load filled bottles on the crates. There are different
electrical devices that are integrated for the operations of this machine which are intended to
specific task. These are mechanical switch, sensors, photoelectric cell, encoders and proximity
switches. The applications of those electrical devices that listed above function as the same as in
un caser robotic machine. The proximity switch used to check whether the filled bottles are fully
placed on the conveyor or not and the other sensor makes sure that six crate are ready to accept
the filled bottles, if the crate is less than six the caser will stop. The other sensors check whether
the filled bottles are arranged exactly to fit with the holes of the machine. There is also another
sensor which used to check other unwanted materials are present in the washed cask. If there are
unwanted materials the machine will stop.
Figure 2. 9: Caser machine
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Palletizer: It is used to send end product beer found in the crates from the conveyor to the
customers. It is replaced by robotic machine rather than using human power. It palletizes 10
crates (240 bottles) at a time. It is controlled by electrical components. such as:
 Servo motor: is used to drive horizontal and vertical movements of robotic machine.
 Inductive sensor (buck up switch): used for the safety of gripper.
 Photo cell: determine distance between bottle and gripper.
 Encoder: control the movement of the gripper.
 Solenoid valve: hold and release the gripper.
Figure 2. 10: Palletizing Machine
Keg machine: In this machine the draught beer is pasteurized and filled in the kegs
automatically.
A keg is a very largely standardized cylindrical metal barrel, made of chrome nickel steel, which
possess a special permanently installed fitting for filling, emptying, cleaning, and sterilization
and which is used for packing draught. There are different photocells and an electric weight
balance work integrated with electro-pneumatic pusher that pushes under and above weighted
kegs. The set weight of draught is 40Kg that means the beer weighs 30 kg and the keg weighs
10kg. If it is less or more than the under filled draught beer will be pushed by electron-pneumatic
pusher.
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Figure 2. 11: Keg machine
2.4 Overall System Components Found in Dashen Brewery Share Company

2.4.1 Programmable logic controller (Plc): is a special form of microprocessor-based
controller that uses a programmable memory to store instructions and to implement functions
such as logic, sequencing, timing, counting, and arithmetic to control machines and processes
and is designed to be operated by engineers with perhaps a limited knowledge of computers and
computing languages. PLC is an industrial computer control system that continuously monitors
the state of input devices and makes decisions based upon a custom program to control the state
of output devices. The type of PLC mostly used in Dashen brewery share company is siemen5
(S5) which is an automation system based on programmable logic controllers. The newer
simaticS7 PLC is used in beer processing section. PLCs:
 Are designed for multiple inputs and output arrangements, extended temperature ranges,
immunity to electrical noise, and resistance to vibration and impact.
 Have interfacing for inputs and outputs already inside the controller
 Are easily programmed and has an easily understood programming language that is
primarily concerned with logic and switching operations. The main application of PLC
in Dashen Brewery S.C is for industrial automation and control of different industrial
equipment’s.
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2.4.2 Components of plc

Typically, a PLC system has five basic components in Siemens’ automation which is used by
Dashen brewery. These are central processing unit, power supply unit, input-output module,
interface module, and communications interface. The figure below shows the basic arrangement.
Figure 2. 12: Major components of Programmable logic controller (PLC)

Power supply unit: The system power supply plays a major role in the total system operation.
It is needed to convert the mains AC voltage to the low DC voltage necessary for the processor
and the circuits in the input and output interface modules. Its responsibility is not only to provide
internal DC voltages to the system components (i.e., processor, memory, and input/output
interface modules), but also to monitor and regulate the supplied voltages and warn the CPU if
something is wrong. The power supply, then, has the function of supplying well-regulated power
and protection for other system components.
Processor or central processing unit (CPU): The function of the processor is to monitor
the state of input devices, scan and solve the logic of a user program, and control on or off state
of output devices. In the CPU the processor works on the program in the memory and queries
whether the individual inputs of the equipment have signal or not. Therefore, we can describe
CPU as: -
 It is the brain of the PLC.
 Consists of a microprocessor for implementing the logic, and controlling the
communications among the modules.
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 Accepts input data from various sensing devices, executes the stored user program, and
ends appropriate output commands to control devices.
Input interface module: Input modules are parts of the PLC where the processor receives
information from external devices and communicates information to external devices. Input
modules converts signal from discrete or analog input devices to logic levels acceptable to PLC’s
processor.
Figure 2. 13: Input interface module
Output interface module: Interface directly to devices such as motor starters and lights.
Output modules take digital signals from the PLC’s processor and convert them to electrical
signals such as 24VDC or 4 mA that field devices can understand.
Figure 2. 14: Output interface module
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Communications interface module: These are intelligent I/O modules that exchange
information between communication networks from or to other remote PLCs which includes
internet protocol communication. It is concerned with such actions as device verification, data
acquisition, synchronization between user applications, and connection management.
Interface module: which is used to connect and understand CPU of the incoming input signals
and the outgoing output signals by converting into CPU language.
2.4.3 Operation principle of plc
PLC operates by continually scanning the program and acting upon the instructions, one at a
time, to switch on or off the various outputs. In order to do this PLC first scans all, the inputs and
stores their states in memory. Then it carries out program scan and decides which outputs should
be high according to the program logic. Then finally it updates these values to the output table,
making the required outputs go high. At his point PLC checks its own operating system and if
everything is ok, it goes back to scanning inputs all over again. PLC’s function using relay ladder
logic programming. Ladder logic allows programmable logic controllers to perform any
command within the loop at any time without executing previous commands. During its
operation, the CPU completes three Processes:
 It reads, or accepts, the input data from the field devices via the input interfaces
 It executes, or performs, the control program stored in the memory system
 It writes, or updates, the output devices via the output interfaces.
Figure 2. 15: Operation cycles of PLC
2.5 Input Devices:
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Input devices are devices that are input to PLC to tell the operating condition of a certain
system. These input devices are mainly called sensors. The term sensor is used for an input
device that provides a usable output in response to a specified physical input. Sensor is a
convertor that measures a physical quantity (e. g temperature, pressure etc.) and converts it into
an electrical signal. There are input devices which convert one type of energy or quantity into
electrical analog signal. Sensors that give digital or discrete, that is, on/off, outputs can be easily
connected to the input ports of PLCs. An analog sensor gives an output proportional to the
measured variable. Such analog signals have to be converted to digital signals before they can be
input to PLC ports. Some of commonly used sensors found in Dashen Brewery Company are
listed below:
Back up switch: Applications of backup switches in Dashen Brewery S.C
 To detect an overload of bottles on the conveyor system
 To detect the presence of filled bottles in filler machine to pack them with cork.
 Control the balance of the in feed and discharge gears at filler machine.
 To detect up and down movement of the robotic machine is at the centering
frame in the caser/UN caser machine.
It works by using comparator, solenoid and copper conductor. There is a set a current value,
when there is an overload, the bottle pushes the conductor and the deviates from preset current
value. This digital current value reaches to PLC based on this value gives appropriate response to
the system. Current is produced through the conductor due to this current loss the current value
at the solenoid. Two types of back up (proximity) switches are available in Dashen Brewery
Company. These are inductive and capacitive back up (proximity) switches.
Inductive proximity switch: Inductive Proximity Sensors detect magnetic loss due to eddy
currents that are generated on a conductive surface by an external magnetic field. An AC
magnetic field is generated on the detection coil, and changes in the impedance due to eddy
currents generated on a metallic object are detected. These sensors are found at conveyor, and
filler machine.
Capacitive proximity switch: Capacitive Proximity Sensors detect changes in the
capacitance between the sensing object and the Sensor. The amount of capacitance varies
depending on the size and distance of the sensing object. An ordinary Capacitive Proximity
Sensor is similar to a capacitor with two parallel plates, where the capacity of the two plates is
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detected. One of the plates is the object being measured (with an imaginary ground), and the
other is the Sensor's sensing surface. The changes in the capacity generated between these two
poles are detected. The objects that can be detected depend on their dielectric constant, but they
include resin and water in addition to metals. These sensors are found in Caser/ Un-caser
machine.
Photo cell: are sensors that allow to detect light. They are small, inexpensive, low power, easy
to use and don’t wear out. Photo cell is basically a resistor that changes its resistive value (in
ohm) depending on how much light is shining onto the squiggly face. It is advices used to detect
the presence and absence of bottles or crates. Some photo cells have two different operational
types, light operate and dark operate. Light operates photo eyes become operational when the
receiver "receives" the transmitter signal. Dark operates photo eyes become operational when the
receiver "does not receive" the transmitter signal. It has sender (LED) and receiver (photodiode)
parts. These two parts may or may not be placed at the same place, if sender and receiver are at
the same place it uses reflectors. The LED emits light and the photo diode receives this light and
change to current signal to input the PLC. Based on this digital signal value PLC gives the
appropriate response to output devices.
Position sensors: Position sensors report the physical position of an object with respect to a
reference point. The information can be an angle, as in how many degrees an object has turned,
or linear, as in how many inches a robot arm has extended. There are two types of position
sensors used in Dashen Brewery factory.
1. A potentiometer: can be used to convert rotary or linear displacement to a voltage.
Actually, the pot itself gives resistance, but as we will see, this resistance value can easily be
converted to a voltage. A pot used to measure angular position has linear taper, which the
resistance changes linearly with shaft rotation. To sense position, the moveable object is
connected directly to the slider/piston of the circuit and a DC reference voltage is applied across
the outer fixed. It is used at the crown cork drive in Dashen Brewery factory.
2. Encoder: It is an electrical input device used for synchronization and position control
purpose. It is an electro-mechanical device that converts the angular position or motion of a shaft
or axle to an analog or digital code. It operates by pulse counting that an object moves. Two
types used in Dashen Brewery Share Company.
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a. Incremental encoder: is quadrature encoder whose output is a series of square wave pulses
generated by photocell arrangement with pulses are counted per cycle of rotation. It operates
with pulses (i.e 1 pulse = 1 rotation of 40 bottles) at Bottle washer machine. It needs external
counter to determine the absolute angle of the shaft. It does not retain its value when power is
turned off.
b. Absolute encoder: used to control both speed and position of caser and UN caser machines as
counter. It provides unique output code for every single position and direction. It operates with
gray code sequence. Its non-volatile memory to retain its exact position of the encoder.
Level sensor: It is a capacitive sensor used to check the status of a container. It is located at the
bottom and top of the container for empty and full inspection. It operates by sensing the change
capacitance and Frequency value. When the dielectric changes, the capacitance value changes
this leads to change in frequency. In Dashen brewery S.C used in brew house to control level of
tank and in filler machine to detect whether the bottle is full or not. Flow sensor: It is a device for
sensing the rate of fluid flow. Typically, a flow sensor is the sensing element used in a flow
meter to record the flow of fluids. Flow meters are devices that measure the amount of liquid,
gas or vapor that passes through them. It is used mostly at brew house.
Pressure sensor: It is used to detect the pressure level of typically gases and liquids. A
pressure sensor usually acts as a transducer it generates signal as a function of the pressure
imposed. When a pressure applied to pressure sensor, the sensor acts to complete electrical
circuit.
Pressure Transducer Current PLC Output devices
Types of pressure sensors found in Dashen brewery share company
1. Absolute pressure sensor
2. Vacuum pressure sensor
3. Electronic manometric switch
Temperature sensor: It is a device used to detect the temperature of liquid, gas, etc. It
commonly used in motor control applications are thermostats and thermocouples. Transducer is
electro-mechanical device which convert physical quantities, such as temperature, pressure to
proportional electrical value, such as voltage or current.
Temperature Transducer Current PLC Output devices
There are four main types of temperature sensors used in Dashen brewery Share Company;
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1. Thermocouple: relies on a principle known as the See back effect. Two dissimilar metal
wires are joined together in a loop with one end being the hot; the other being the cold junction.
A difference of potential is generated in the loop in response to temperature change. Each of
these devices sense temperature change and then presents a contact closure for use in a control
circuit.
2. Thermostat: is a contact type electromechanical temperature sensor or switch that is used to
control heat in control rooms and control boxes.
3. Thermistor: a thermistor is a two-terminal device that changes resistance with temperature.
Thermistors are temperature sensitive resistors That is, if temperature is high, resistance are low
and vice versa. Thermistors are of two types, PTC and NTC. PTC refers to materials that
experience an increase in electrical resistance when their temperature is raised. NTC refers to
materials that experience a decrease in electrical resistance when their temperature is raised. It is
used to control the heating of induction motors in Dashen brewery by being inserted inside the
rotor winding.
4. PT100 temperature sensor: is most commonly available of Platinum Resistance
Thermometer (PRT’s) which is used to measure the resistance of a platinum element. It is used
in bottle washer machine to measure the temperature of the caustic, which is used to wash the
dirty bottles <= 80 °C. It has a resistance of 100 ohms at 0 °C and 138.4 ohms at 100 °C.
2.6 Output Devices
The output ports of a PLC are relay with transistor or track, depending on the devices that are to
be switched on or off. Generally, the digital signal from an output channel of a PLC is used to
control an actuator, which in turn controls some process. The term actuator is an output device
that transforms the electrical signal obtained from PLC into some more powerful action, which
then results in control of the process. Some kinds of actuators found and used in Dashen Brewery
factory are; motors, pneumatic actuators/valves, hydraulic pistons, timers or time delay relays,
electrical control relays, solenoid valves, contactors etc.
2.6.1 Drive motors
There are many electrical motors that are used for different purpose. Such as: ac motors
(synchronous and induction motor), dc motor and servo motors. Three kinds of motors mostly
used in Dashen Brewery Factory. i.e three phase induction motors, synchronous motor and
servomotors.
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2.6.1.1 Synchronous motor

Those motors are doubly exited fed type and have direct current in their field windings and ac
armature windings. This motor is mainly used at washer machine for the purpose of driving
bottle chain holders.
2.6.1.2 Induction motor
It is a singly fed type motors which carry ac current in both stator and rotor winding. It is a type
of electric motor that converts electrical energy in to mechanical energy in which alternating
current from a power source is fed through a primary winding and induces a current in a
secondary winding, with the parts arranged so that the resulting magnetic field causes a movable
rotor to rotate with respect to a fixed stator. It is mainly used for the purpose of driving the
conveyer chain and compress.
2.6.1.3 Servo motor
It is mainly used at the two robotic machines (caser and UN caser) to control the position of
grippers at the desired place. A servo motor is a linear or rotary actuator that provides fast
precision position control for closed-loop position control applications. Unlike large industrial
motors, a servo motor is not used for continuous energy conversion. Servo motors work on servo
mechanism that uses position feedback to control the speed and final position of the motor. A
servo motor consists of small dc motor, encoder, gear arrangement and an intelligent control
circuit. The intelligent circuit along with the encoder makes the servo to rotate according to our
wishes. The feedback device consists of an absolute encoder with a potentiometer to detect
position and speed.
2.6.2 Relay
Relays are electro-mechanical devices used to turn pilot lights on and off, control mechanical
equipment, and send signals from a sensing device, such as a float switch, to another component,
such as a motor. The current flowing in one circuit causes the opening or closing of another
circuit. The contacts of a relay may be normally open (NO) or normally closed (NC).
2.6.3 Contactor
Contactor is an electrically controlled switch used for switching an electrical power circuit,
similar to a relay except with higher current rating. A contactor is controlled by a circuit which
has a much lower power level than the switched circuit. Unlike circuit breaker, a contactor is not
intended to interrupt a short circuit current. Unlike general-purpose relays, contactors are
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designed to be directly connected to high-current load devices. Devices switching more than 15
amperes or in circuits rated more than a few kilowatts are usually called contactors. When
current passes through the electromagnet (pins A1 and A2), a magnetic field is produced, which
attracts the moving core of the contactor. The electromagnet coil draws more current initially,
until its inductance increases when the metal core enters the coil. The moving contact is
propelled by the moving core; the force developed by the electromagnet holds the moving and
fixed contacts together. During this time the motor or any electrical output device connected to
the contactor is activated. When the contactor coil is de-energized, gravity or a spring returns the
electromagnet core to its initial position and opens the contacts, and hence output devices turned
off. Contactors are used to control electric motors, lighting, heating, capacitor banks, thermal
evaporators, and other electrical loads.
Figure 2. 16: Contactor
2.6.4 Solenoid valve

Solenoid valve is an electrically actuated on/off valve. The solenoid part of the valve is always in
one of two possible states, it's either energized or de energized. There is a single moving part
inside the solenoid typically iron rod that is influenced by the magnetic field which develops
when the solenoid's coil is energized. Thus, energizing causes a change of position of the rod
which causes a change of position of the valve. These valves are not capable of modulating
action because they cannot modulate a solenoid. Unlike a motor operated valve, a solenoid will
have a failure position, and when it is not energized, it will be in the failure position. A solenoid
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valve has two main parts the solenoid and the valve. The solenoid converts electrical signal into
mechanical energy which in turn opens or closes the valve mechanically.
2.7 Electric Power Distribution
The company power supply is 15kV gained directly from high transmission power lines of
Ethiopian Electric Power Corporation (EEPCO) substation. This high voltage is transmitted to
the two parallel connected three-phase transformers by copper cable. The two transformers share
the 15kV load, their working principle is based on the principle of parallel connection of
transformer. The transformers primary winding is star connection and the secondary winding is
delta connection. These transformers step down the supply 15kV voltage into the required
voltage which is 380V-400V, each of the transformers have switch gear and also have change
over switch which uses to isolate the transformer when maintenance is required. It has two oil
immersed transformer connected in parallel its rating power 630kVA, load current 1600A,
ambient temperature 40℃, rated frequency 50hz and transformer failure temperature above
50℃. When EEPCO power is switched off diesel AC generator starts after transformers are
isolated by switching gear. This generator is capable of fulfilling all power needs of the
company. When there is power fluctuation there is reserved diesel AC generator which generates
about 1.8MW and couples to the transformers by bus coupler. The AC emergency diesel
generator is standby and it’s on/off controlled by timer.
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Figure 2. 17: block diagram of power consumption for Dashen brewery
Dashen brewery factory gets electric power from EEPCO. Necessary conditions to operate three
phase transformers in parallel are:
 The electromotive forces should be equal in magnitude and phase in order to avoid
circulating currents and permit good load sharing.
 The per-unit impedances (or percentage impedances) should be equal in magnitude and
have the same angle. i.e the X/R ratios should be the same.
 The transformer ratio should be the same.
 The transformers must have the same phase displacement between primary and
secondary line voltages. i.e they must belong to the same group number.
Some of the main advantages of operating transformers in parallel are:
1. Non-availability: of a single large transformer to meet the total load requirement.
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2. The power demand might have increased over a time necessitating expansion of the
capacity.
3. To ensure improved reliability. Even if one of the transformers gets into a fault or is taken
out for maintenance/repair the load can continued to be serviced.
4. To reduce the spare capacity. If many smaller size transformers are used one machine can
be used as spare. If only one large machine is feeding the load, a spare of similar rating has to be
available. The problem of spares becomes more acute with fewer machines in service at a
location.
5. When transportation problems limit installation of large transformers It may be easier to
transport smaller ones to site and work them in parallel.
2.8 Major Duties of the Intern
Internship provides the opportunities to build a relationship with the company, network with
other people in the field and gain valuable first-hand experience. It gives us the knowledge and
experience. We understand that our duties include the following tasks.
 To be punctual
 Obey the rules and regulation of the company
 Work the given tasks in the company with the guidance of the company supervisor
2.9 Challenge Faced and Measures Taken
2.9.1 The challenge we faced
The major challenge as soon as we entered in to the company was to be able to be familiar with
the staff members specially persons who are found in administration. Hence, they don’t perceive
us as a staff member; they don’t give us any detail information about the company. The other
problems we faced in the company are; lack of enough office equipment’s like computers. We
haven’t theoretical knowledge about programmable logic controller (PLC) before the internship
so it was difficult to easily understand it.
2.9.2 The measures we have taken
In order to be familiar with the electrical devices, we first tried to observe them with the
electricians by asking about them repeatedly to enable us know the electrical devices and control
elements. To overcome the communication problem, we tried to communicate with all staffs
through the staffs that we know before and cooperating with all staffs in order to have healthy
and successful working.
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CHAPTER THREE
3. OVERALL BENEFITS THAT WE GAINED FROM THE INTERNSHIP
We faced that the internship time was the most educating and challengeable time. We see how
well, we have understood the theories and formulas we had taken in our previous courses but
when it comes to the actual world, it was hard to tell how competent we were. It is very
understandable that parallel to the theoretical part, experience is very important in real world.
Being familiar with the work flow is a key to understand one’s role properly and be able to make
competent decisions. In our internship too, there were some benefits gained accordingly. The
benefits are discussed below.
3.1 Theoretical and Practical Skill
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When we first started on the company everything was new for us. It was really fascinating and
inspiring to see and experience the lessons we have been learning for the past three years. As it’s
commonly practiced, most of the courses we took in class dealt with the theoretical side of it.
Some lecturers took the initiative and tried to illustrate the practical part of this field by
displaying different graphic images in their lecture or suggested electrical device and equipment
that were more or less illustrative or even show us in laboratory to show what the actual work
looked like. The theoretical concepts that we know before helps us to develop our practical skill.
We spent most of our time with the Dashen brewery electricians to develop our practical skills,
theoretical skills, working procedures, proper use of materials and identifying the right material
for the right purpose. This internship program provided us with the opportunity to expand our
horizon, broadening our intellectual knowledge and gives us a chance to improve our theoretical
and practical knowledge from this grateful experience. Generally, we gained the following
essential things.
 Creative and logical approach to solve problems.
 Clearly understand different electronic devices working principle and interconnection.
 We understand the control and power distribution system in the industry.
 Effective assessment and management of risk, resource & time.
 To be familiar with the operation principle, control mechanism, and networking system
about programming logic controller (PLC).
 To analyses the starting and speed control mechanism of electric motors.
 We got an experience to read and interpret information and ideas presented in electrical
documentation drawings for different types of electrical machines. All the electrical
maintenance and installation system is based on the electrical documentations designed
by engineers.
3.2. Improving Team Playing Skills
We learn a lot how to improve interactions with our team members. When activities are done in
group the acceptability, reasonability and accuracy found to be always better than those done
individually. Therefore, we really understand team work is important to strength the effort to
accomplish the task. Ideas that are raised in team work help us to see one thing in different
angles and to be a multi directional thinker for elaborating our knowledge regarding the given
issue. We understand that for the proper functioning of a team, each member should have:
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 Good communication skill

 Fast decision-making skill
 Self-confidence
3.3 Interpersonal Skills
Another benefit we gained from the internship experience is the importance of smooth
relationship communication skill for effective and fruit full work. In this regard we were working
together not only with corporation workers but also with regular students who came for
internship as we did. This situation gave us a chance to improve our interpersonal
communication.
3.4 Improving Leadership Skills
We got the opportunity to compare my leadership principles with the leaders/managers in the
company. Our leadership principles are: firstly, thinking globally not personally then respect,
listen and work with all concerned bodies of the company. In dashen brewery there are managers
who follow the same principles similar to us. These managers lead honestly as per rules and
regulations of the company. We also got practical skills of that leadership can influence others to
work towards the achievement of the desired service and it is one of the functions of
management which includes planning, organizing, staffing, leading, and controlling. When we
take a part as a leader, we must not make it personal and don ‘t rush in to for personal attack. In
the other hand we have to change or modify our own position when we got other person ‘s idea
is better and more convincing. The overall benefit that we gained from the internship regarding
improving leadership
CHAPTER FOUR
4. IDENTIFED PROBLEMS AND SOLUTIONS PROPOSED
4.1 Identified Problems
In Dashen Brewery Share Company there is a problem we have seen when we were practicing in
our internship period. This problem is:
 Tap changer of power transformers are not do automatically.
4.2 Solution Proposed
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 power transformers are do automatically in the company it is better to design stepper

motor based automatic tap changer for power transformer.
4.3 Abstract
A tap changer is a component of a transformer. It controls the transformer's output voltage by
adjusting its winding ratio within some range of step levels. Transformer tap changing is a wide
issue that necessitates a great deal of attention in transformers. Because of load instability, the
power system has a lot of issues. Tap changer is used manually operated and to change even if a
single one tape it needs to be rotated manually many times by using hand crack and it needs
continuously to be checked by operators. This makes the tap monitoring not to be done quickly
and not to give accurate adjustment. This lead sudden accident or faults on the transformer. The
goal of this project is to create and simulate a system that uses an automatic microcontroller-
controlled stepper motor to modify the transformer's turn ratio in an on-load condition. The
system consists of stepper motor, microcontroller, voltage sensor and current sensors that
installed on transformer. Finally, in this project, Arduino microcontroller is used to develop and
simulate a stepper motor-based automatic tap changer of a power transformer.
Keywords: Transformer, microcontroller, voltage sensor, stepper motor.
4.4 Introduction
4.4.1 Background of study
The production of the on-load tap changers started in 1952 with the creating of the first tap
changers of the series having modern construction developed on the grounds of the constructions
of the Austrian organization. These on load tap changers were determined for the demands of the
Bulgarian transformer manufacturers. In modern power transformers on load tap changer is
equipped with the automatic tap changer. But in these methods between two instants, it is
considered only the changes in the load side but not in the supply side of the system. Thus, for
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long time interval there will be consideration of supply system side also. But for shorter time
there will be not much variation in the measurements results to the impossible to estimate the
equivalent. Even though different processing of data techniques is used to raise the precession of
the equivalent value there is no decay in the problem. Now a days almost all the large power
transformers are provided with on load tap changers and this project is automatic tap changing to
make the operation efficient and to reduce response time. Previous works are done to make
automatic tap changing using selector switches and gears but they are more exposed for short
circuit during transition of taps due to high response of time but we are going to use stepper
motors which have exact and accurate positioning with very short response time in coordination
with micro-controller and different sensors. Taps are leads or connections provided at various
points on the winding. The turn ‘s ratios differ from one tap to another and hence different
voltages can be obtained at each tap. System voltage control is essential for adjusting the
terminal voltage of consumer within the prescribed limits.
4.5 Statement of the Problem
Transformer tap altering is a broad issue that necessitates a great deal of attention in
transformers. Because of load instability, the power system has a lot of issues. Tap changer is
used manually operated and to change even if a single one tape it needs to be rotated manually
many times by using hand crack and it needs continuously to be checked by operators. This
make the tap monitoring not to be done in fast response and in accurate calibration. Having no
fast response time is leads to outage of system due to unbalanced operation of transformer with
the variation of load and sudden accident or faults on the transformer happen due to long arcing
time which leads to short circuit on the transformer tap mounting. Furthermore, the classic
OLTC transformer's mechanical regulating tap-changer generates an electric arc during the tap-
changing operation, and because the tap-movement changer's speed is slow, the regulating
response time is long. Mechanical drive components, brushes, and contractors all need to be
maintained and/or replaced on a regular basis. Brushes can be damaged by frequent overloads.
For electronic loads, the voltage correction speed may not be fast enough. It has a high failure
rate, is difficult to maintain, and is unable to precisely regulate time. As a result, this type of
mechanical on-load tap changer has not been able to fully satisfy the security of today's electrical
network as well as the demand for cost-effective movement. Using a stepper motor and a
microcontroller, this project designs an automatic system with a quick response time and precise
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positioning of the transformer tape. As a result, the project designed to be low-cost and operate
quickly and reliably in order to protect the transformer's health.
4.6 Objectives of the Study
4.6.1 General objective
 The main aim of this project is to design stepper motor based automatic tap changer for
power transformer.
4.6.2 Specific objectives
 To design Automatic tap changer circuit.
 To develop a circuit for stepper motor control.
 To simulate the model system with microcontroller using Proteus.
4.7 Significance of the Study
 To avoid the problem of direct manual checkup of transformers by displaying the output
voltage and current and also taping level of tape changer on LCD.
 To regulate the output voltage of a transformer.
 To protect sensitive equipment’s in the company and transformers from damage.
 To make the tap monitoring have fast response.
4.8 Scope of the Project
The scope of this project contains software design and build the circuit diagram of the entire
system. The circuit part mainly consists of a stepper motor driving unit, voltage sensor, current
sensor, tap changer and LCD display circuit. The software simulation of this project has done by
using Arduino with Proteus.
4.9 Literature Review

A very large work has been done on observing and checking of transformer, some of those
researches which had been organized and carried out, their delays, uncertainties and returns are
as discussed in the following paragraphs.
Nikunj R. Patel, et al [1] presented on” on-load tap changing (OLTC) regulators using fuzzy
logic controller”. They ensure a good regulation of the output voltage in presence of large
variations of the input voltage with typical response time from several mili-seconds to several
seconds. Earlier mechanical type of on load tap changers were into practice. But they had
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considerable limitations and drawbacks like arcing, high maintenance, service costs and slow
reaction times.
Miles A Redfern et al [2] proposed on “The enhancements to the AVC control scheme using
source drop compensation and pre-emptive tap changing” they enable the voltage control offered
by the OLTCT to be improved. On-load tap-changer transformers (OLTCT) provide a well-
established method for controlling the voltage on supply networks. Their associated automatic
voltage control relays (AVC) include a selection of features to ensure that they enable the
voltage to be controlled at a nominal supply point rather than just the transformer.
R. Shuttle worth et al [3] stated on “mechanical on-load tap changing power transformer with
the use of high-power semiconductor” they use high power semiconductor devices such as triac,
IGBTs, Thyristor, problems related with the mechanical on-load tap changing power transformer
have been eliminated. In order to overcome these limitations and drawbacks, new circuits and
configurations for tap-changers have been introduced.
Smith C A, Potts S C et al [4] proposed on “Simulation Studies of OLTC Transformer AVC
relays Operating in Series using a RTDS, real time digital simulator”. They implanted by
hardware and they regulated the output voltage of transformer. However, they do not obtain the
fast response and due to not fast response time leads to the system outages.
From the related research works discussed it has observed that, related controllers have used for
the on-load tap changer of a transformers. Simulations and hardware implementations have
performed in some of these related research works which is appreciated. However, the stepper
motor based automatic tap changer of transformer has not been covered. Hence, the gaps
observed in these related works solved in the thesis work.
4.10 Methodology
In this project, we design stepper motor based automatic tap changer power transformer by
collect data from books, different websites and using appropriate materials. These design process
requires microcontroller, proteus software for easy showing the result and testing of the project.
As result to perform regulate the output voltage of a transformer, to avoid the problem of direct
manual checkup of transformers and to make the tap monitoring have fast response. Finally, we
simulated proteus software.
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4.10.1 Procedure of the study

 Problem identification: first identifying the problem.
 Literature Review: Studying literature on different related project work studied and
different concepts adopted.
 Data collection: Data collection from different source. since gathering information and
data is vital to do research project, we try to review random reference and books and
helpful tutorials to make the project done.
 System Modeling and Design: is selecting appropriate components to model and design.
 Simulation: the modeled and designed systems is tested and simulated using Arduino
and proteus.
 Materials: only software. The software components are Arduino software IDE 1.8.2 for
writing the code or program and Proteus 8 Professional for building the circuit and
running.
Figure 4. 1: Methodology flow chart
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4.10.2 Project methodology
Figure 4. 2: Block diagram of the system
4.11 Block Diagram Description

Power transformers: are electrical instruments used in transmitting electrical power from one
circuit to another without changing the frequency. They operate by the principle of
electromagnetic induction. Power transformers are used to step up or step down the voltage in
distribution networks. Since they have no rotating or moving parts, these instruments are
considered static devices. These instruments work based on an alternating current (AC) electrical
system.
Figure 4. 3: power transformer
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Rectifier: is an electrical device that converts alternating current (AC), which periodically
reverses direction, to direct current (DC).
Figure 4. 4: Circuit diagram and waveform for bridge rectifier
Arduino microcontroller Controller: is the main part of the system where all the process flow
will be controlled by this hardware according to the embedded programming in it.
Microcontroller is chosen for the system as the controller. In other word it is the heart of this
device system. Arduino is a tool for making computers that can sense and control more of the
physical world than desktop computer. It's an open-source physical computing platform based on
a simple microcontroller board, and a development environment for writing software for the
board Arduino can be used to develop interactive objects, taking inputs from a variety of
switches or sensors and controlling a variety of lights, motors, and other physical outputs.
Arduino controller or the Arduino Uno has a number of facilities for communicating with a
computer, another Arduino, or other microcontrollers.
Figure 4. 5: Arduino uno microcontroller
Liquid crystal display (LCD): The LCD is a 14-pin device in a row. The voltage Vcc (voltage
collector collector) and Vss (voltage source source) provided by +5V and ground respectively
while Vee (voltage emitter emitter) is used for controlling LCD contrast. Variable voltage
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between ground and Vcc is used to specify the contrast of the characters on the LCD screen.
When sufficient voltage is applied to the electrodes, the liquid crystal molecules would be
aligned in a specific direction. The light rays passing through the LCD would be rotated by the
polarizer’s, which would result in activating / highlighting the desired characters. The LCDs are
light weights with only a few millimeters thickness. Since the LCD’s consumes less power, they
are compatible with low power electronic circuits, and can be powered for long durations. The
LCD don’t generate light and so light is needed to read the display. By using back lighting,
reading is possible in the dark. It consists of two lines, 20 characters per line that is interfaced
with the Arduino uno.
Figure 4. 6: LCD
Current sensor: Current transformer used in this project to sense a current in the transformer.
Voltage sensor: Voltage transformer are used in this project to sense the voltage value of
secondary voltage, this sensor is the eye of the tap changer, which it operates properly by the
action of steeper motor through microcontroller.
Motor drive: is an electronic device that helps convert electrical energy into mechanical energy.
Therefore, a motor driver allows you to conduct automatic works using electrical power. Motor
drives can control its speed making it possible to enhance process control, reduce energy usage
and generate energy efficiently or optimize the operation of various applications relying on
electric motors.
Stepper Motor: Stepper motor is an electro mechanical device that convert electrical energy
into mechanical energy. A stepper motor has stator part and rotor part and that rotates in discrete
step raises. The movement of each step is accurate and repeatable, therefore the motor's position
can be controlled precisely without any response mechanism, as long as the motor is carefully
sized to the application. Stepper motor brushless motor and it is also known as stepping motor. It
43
has small size and it complete the specific task correctly. These motors have excellent response
to starting, stopping and reversing. Advantages of step motors compared to other types of motors
are low cost, high reliability, high torque at low speeds and a simple rugged construction that
operates in almost any environment.
Figure 4. 7: Stepper motor circuit diagram
4.11.1 Operation of stepper motor:

The fundamental working principle of a stepper motor is energizing a coil winding creates an
electromagnetic field with a north and south pole. Once discrete DC voltage is applied to the
winding of the stator, one or more of the stator phases gets energized and a magnetic field is
generated by the current flowing through the stator coil. The rotor aligns with this magnetic field,
which causes it to rotate at a particular angle called the step angle. By energizing different stator
phase in sequence, you may make the rotor circulate by a selected range of steps (one step at a
time) to reach the desired final position. Stepper motors are usually synthetic or manufacture
with 12, 24, 72, 144, 180 and 200 steps in line with revolution and a corresponding step angle of
30º,15º, 5º, 2.5º, 2º, and 1.8º. You can operate a stepper motor without or with feedback control.
When operated without feedback control, the stepper motor can be controlled by way of
energizing every stator section one at a time
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Figure 4. 8: operation of stepper motor
Tap changer: A tap changer is a mechanism in transformer which allows for variable turn ratios
to be selected in distinct steps. This is done by connecting to a number of access points known as
taps along either the primary or secondary winding. The purpose of a tap changer is to regulate
the output voltage of a transformer. It does this by altering the number of turns in one winding
and thereby changing the turns ratio of the transformer. There are two types of transformers tap
changers: and a deenergized tap changer (DETC)and an on-load tap changer (OLTC).
1. Off load tap changing: is also called de-energized tap changer (DETC), these mechanisms
require the transformer to be isolated before its tap setting can be adjusted. In Off load type Tap
Changer can only carried out when the transformer is de-energized. The tap changer can be
operated by a handle or wheel from the outside of the tank in most transformer.
2. On load tap changing: are used to change the turn ‘s ratio without disconnecting the load
from it. Tap changing can be completed even the minute the transformer is carrying load. On-
load tap changers (OLTCs) are the essential components for the regulation of power transformers
used in electrical energy networks and industrial application. On load tap changers considerable
increases, the efficiency of the system. Nowadays almost all the large power transformers are
provided with on load tap changers and this project is automatic tap changing to make the
operation efficient and to reduce response time
4.11.2 Location of tapping
The tapping is provided at the HV winding of the transformer because the high voltage winding
is wound on the low-voltage winding. If we connect tap changer on the LV side then sparking
will take place. Also, the current in the HV winding of the transformer is smaller due to which
small contacts and leads are required for tapping connections. The tap changer is operated by a
motor operated driving mechanism of local or remote control. The handle is operated for manual
operation in case of an emergency.
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Figure 4. 9: Tap changer location
4.11.3 Operation of tap changing

The tap change operation takes place in two steps; first the next tap is preselected by the tap
selector at no load, then the diverter switch transfers the load current from the tap in
operation to the preselected tap. The OLTC is operated by means of a drive mechanism. Now if
we want to change the tap position from tap-1 to tap-2, operates the drive unit steeper motor
through raise control switch. The motor starts operation (at this time only an action starts in
diverter switch because tap -2 is already Selected). For changing the tap-1 to tap-2 the voltage
will be increased on secondary side of transformer because the numbers of primary turns have
now reduced. Similarly, if we want to go on tap no.3, the operational sequence will be same as
above but in reverse (side 2 to side 1) and now the operation will become at first in selector
switch, as the odd moveable selector selects the tap no.3. For doing continuous changing the taps
in step by step, we select the tap-5. At this time only a main winding will be in circuited and
current will flows from A to B by the main winding to diverter switch. The tap-5 of this
arrangement is called principal tap. At this tap the voltage on both sides will be rated. Now if we
want further changing in taps, operates the motor through the raise switch placed in drive units.
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15K
Figure 4. 10: Block diagram for OLTC power and control scheme
4.11.4 System design and analysis

Mathematical calculation:
The turns ratio of the transformer is given by the following equation:
N1
Turns ratio= (4.1)
N2
Where N1 and N2 are number of turns on primary and secondary. From transformer theory we
know that the turns ratio on primary and secondary of the transformers equal to voltage on
primary and secondary.
V1 N1
Which means: = (4.2)
V2 N2
Where V1 and V2 are the voltage on primary and secondary. So, for calculate the voltage ratio
we use the following equation.
V1
Votage ratio= (4.3)
V2
15 kv
Voltage ratio=
400 v
The formula of tap percentage is given by the following equation:
Vactual−Vrated
Tap %= (4.4)
Vrated
At normal operation tap 3 is the high voltage winding read 15KV and it gives 400V in the low
voltage side.
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To calculate the output voltage of tap setting we use the following equation:
V
Vactul=tap % × (4.5)
100
Vlimit =V +Vactual (4.6)
At 2.5% the high voltage winding is:
15000 v
2.5 × =375 V
100
15000+375=15375 V
And similarly in low voltage side
400 v
2.5 × =10V
100
400 +10=410 V
In case of 5%
15000 v
5× =750 V
100
So, high voltage side will have voltage of:
15000+750=15750 V
And low voltage (LV) side will have voltage of:
400 v
5× =20V
100
400 +20=420 V
And in decreasing of load at -2.5% HV side will have
15000−375=14625 V
At LV side will have
400 V −10=390 V
At -5% high voltage side will have
15000−750=14250 V
At low voltage side voltage will have
400−20=380 V
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Table 4.1: showing arrangement of taps with voltage limit.

Number of taps Voltage at HV side Voltage at LV side
Tap 1 15750 420
Tap 2 15375 410
Tap 3 15000 400
Tap 4 14625 390
Tap 5 14250 380
In this project voltage transformer has five taps on the primary winding giving -5%, −2.5 % ,
+2.5, +5% and 0% turns.
Case1:
If on-load, the secondary voltage increases to 420V then, the tap should be used to maintain at
400V on-load (assuming the supply voltage remains constant).
Examining the relationship:
V1 N1
= ∨V 1 × N 2=V 2 × N 1 (4.7)
V2 N2
This indicates that, to keep the equation in balance with primary voltage and secondary winding
turns fixed, either V2 or N1 must be adjusted. Since the objective is to reduce V2 back to
nominal, then N1 must be decreased.
400
To reduce V2 from 410V to 400V requires decrease in secondary volts of =0.9756∨98 % .
410
1
N1 must be increased to =1.025
0.95
Therefore, N1 must be increase by (1.025−1=0.025) or 2.5%.
Increasing N1 by 2.5% will accomplish reduction in secondary voltage output. According to our
tap setting it will select tap number 2.
Case 2:
If on-load the secondary voltage increases to 420V then, the tap should be used to maintain 400V
on-load (assuming the supply voltage remains constant).
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Examining the relationship using equation:

V1 N1
= ∨V 1 × N 2=V 2 × N 1 (4.8)
V2 N2
This indicates that, to keep the equation in balance with primary voltage and secondary winding
turns fixed, either V2 or N1 must be adjusted. Since the objective is to reduce V2 back to
nominal, then N1 must be decreased.
To reduce 420V to 400V requires decrease in secondary volts of

400 1
=0.9523∨95 % . N1 must be increased to =1.05
420 0.95
Therefore, N1 must be increase by ( 1.05−1=0.05 ) ∨5 %
Increasing N1 by 5% will accomplish reduction in secondary voltage output. According to our
tap setting it will select tap number 1.
Case 3:
At normal voltage limit our tap changer cannot change position and it is fixed at tap number
V1 N1
= ∨V 1 × N 2=V 2 × N 1 (4.9)
V2 N2
Case 4:
If, on-load, the secondary voltage reduces to 390 V then, the tap should be used to maintain 400
V on-load (assuming the supply voltage remains constant) is
Examining the relationship in equation:
V1 N1
= ∨V 1 × N 2=V 2 × N 1 (4.10)
V2 N2
This indicates that, to keep the equation in balance with primary voltage and secondary
winding turns fixed, either V2 or N1 must be adjusted. Since the objective is to raise V2 back
to nominal, then N1 must be reduced.
To raise V2 from 390V to 400V requires an increase in secondary voltage of:
400 V
=1.0256
390 V
1
N1 must be reduced to: =0.975
1.0256
Therefore, N1 must be reduced by (1-0.975=0.025) or 2.5%. Reducing N1 by 2.5% will
accomplish the increase in secondary voltage output.
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According to our tap setting it will select tap number 4.

Case 5:
If on-load, the secondary voltage reduces to 380V then, the tap should be used to maintain 400V
voltage on-load (assuming the supply voltage remains constant) is Examining the relationship
V1 N1
equation: = ∨V 1 × N 2=V 2 × N 1
V2 N2
This indicates that, to keep the equation in balance with primary voltage and secondary
winding turns fixed, either V2 or N1 must be adjusted. Since the objective is to raise V2 back
to nominal, then N1 must be reduced.
To raise V2 from380 to 400V requires an increase in secondary voltage of:
400 V
=1.0526
380 V
1
N1 must be reduced to: =0.95
1.0526
Therefore, N1 must be reduced by (1-0.95=0.05) or 5%.
Reducing N1 by 5% will accomplish the increase in secondary voltage output.
According to our tap setting it will select tap number 5.
The nearest tap to select is -2.5% (see Figure)
Figure 4. 11: Tap selection process
4.11.5 Overall system flow chart

Tap selection logic is shown in the figure below. The microcontroller continuously reads the
value of the input voltage using voltage sensor. It checks whether the input voltage is within
prescribed voltage limits. If the voltage is within the predetermined limits the tap will be rotated
as per programed.
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Figure 4. 12: Flow chart of overall tap changing system
4.12 Result Analysis and Discussion

The design of microcontroller-based stepper motor automatic tap changer was simulated by
using proteus software, it is designed by using different parts integrating together it consists of
microcontroller, voltage sensor, current sensor, bipolar stepper motor, ULN2003A driver.
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4.12.1 Overall circuit diagram of system
Figure 4. 13: System circuit design
As being mentioned previously the system shows the conditions of the transformer tap changer
load voltages. The system checks two parameters whether or not the voltage varies. The sensors
send a signal to the microcontroller, and it also sends a command for a steeper motor for
changing turn ratio of a transformer. The Microcontroller also sends the monitored parameters to
LCD display. When voltage is between 380v-398.63v the voltage sensor changes sensed current
signals to voltage and feed to micro controller, the value of voltage displayed on LCD, stepper
motor rotates then the tap number on LCD displayed is “Tap No:5” and finally the transformer
operates in balance with load demand.
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Figure 4. 14: Arduino microcontroller stepper motor based automatic tap changer for tap-five
When voltage is in between 398.63-400v the voltage sensor changes sensed current signals to
voltage and feed to micro controller, the value of voltage displayed on LCD, steeper motor
rotates then the tap number on LCD displayed is “Tap No:4” and finally the transformer operates
in balance with load demand.
Figure 4. 15: Arduino microcontroller stepper motor based automatic tap changer for tap-four
When voltage is 400v transformer operate in balance with load demand. The voltage sensor
signals sense the value of load voltage and feed to micro controller and the value of load voltage
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displayed on LCD, stepper motor not rotate in this condition, then tap number is display on LCD
displayed.
Figure 4. 16: Arduino microcontroller stepper motor based automatic tap changer for tap-three
When voltage is in between 400v-410v the following events are undertaken: voltage sensor
changes sensed current signals to voltage and feed to micro controller, the value of voltage
displayed on LCD, stepper motor rotates, then tap number on LCD displayed is” Tap No:2”,
finally the transformer operated in balance with load demand.
Figure 4. 17: Arduino microcontroller stepper motor based automatic tap changer for tap-two
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When voltage is in between 400v-420v the following events are undertaken: voltage sensor
changes sensed current signals to voltage and feed to micro controller, the value of voltage
displayed on LCD, stepper motor rotates clock wise, then tap number on LCD displayed is “Tap
No:1”, finally the transformer operated in balance with load demand.
Figure 4. 18: Arduino microcontroller stepper motor based automatic tap changer for tap-one
4.13 Conclusion and Recommendation

4.13.1 Conclusion
It is an ordinary truth that increases in load lead to decrease in the supply voltage. after the
voltage supplies by the transformer to the load should be maintained within the given limits. This
can be completed with the help of changing the transformer turns ratio. The taps are leads or
connections at various points on the winding. In this project work stepper motor based automatic
tap changer with five taps that placed at high voltage side of transformer is designed. In this
project we have developed automatic system which has fast response time and accurate
positioning of the transformer tap using stepper motor aided by microcontroller. In this project
work any variation at the output voltage of transformer is sensed by way of the microcontroller
and compare with the reference value as per the program. Then stepper motor is begin rotating to
change the tap position as needed. From the simulation result better and fast time responses are
obtained with automatic stepper motor-based tap changer.
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4.13.2 Recommendation
In our recommendation we recommend that any transformer manual checkers to apply this
stepper motor-based tap changer system. Any work on tap changing is very advantageous. Based
on the present time, it can be observed that the world ‘s population is increasing rapidly.
Therefore, demands on electricity will be high and these will lead to demands of highly
protection devices, and tap changer which will be combined in transformer tap changer systems.
from this project work the following points are recommended for further studies:
 we also recommended that it can be done by more modifying this tap changing system by
adding additional tap levels, we only work on 5 voltage level taps, it means our tap
changer is designed for transformer which contains 5 taps.
 The system is made up of two system electrical and mechanical system; we have shown
simulation result for full of the electrical part and some parts of mechanical part and the
remaining part is only possible to show in implementation.
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CHAPTER FIVE
5. CONCLUSION AND RECOMMENDATION
5.1 Conclusion
Generally, this internship period was interesting because it enables us to get practical knowledge,
improve our practical skill, upgrading our theoretical knowledge, improving team playing skills,
improving leadership skills and understanding about work ethics related issue. In addition to this
we have been familiar with the following concepts.
 How to control the overall mechanical and electrical system of the industry.
 Stimulate new interest in academic course work and frequently developed and Inter
disciplinary perspective.
 Gain an increased awareness of skill, attributes and personal qualities and values.
 How the overall production of beer is automated and controlled by PLC. We have gotten
a general overview of raw materials, chemicals added, utilities needed and overall
process to produce the required Dashen beer.
 Replacing relay control systems by PLC had a great benefit on the production process.
5.2 Recommendation for Dashen Brewery Share Company
We would like to give the following recommendations for the company based on our
observations while we were conducted in our internship period.
 In wastewater treatment plant there is unpleasant odor which causes for human health
problem and environmental pollution. To overcome such problem the company should
use advanced wastewater treatment (such as tertiary treatment).
 The Company has less experienced professional human power. Engineers found in the
company give repair, maintenance and operating controls. But if certain equipment were
stop working it would be replaced or maintained by other country engineers via
worldwide network. Instead of this action it is better to learn our engineers and fix
problems.
 The Company had administration problem while accepting internship students. It accepts
many students over its ability. Rather than doing this it is better to accept limited students
and give better service in practice and safety requirements for them.
 It is better to design new ear sound damper rather than using the old one to protect the
workers ear from damage.
58
5.3 Recommendation for University

The university industry linkage should work in better coordination with the industries by creating
project proposals in how the students shall be treated in industries to achieve experiences. The
university should give necessary courses related to industry automation control systems like
before they are engaged in internship program. While the students are engaged in internship
period, university industry linkage should have better communication networks to the industries
to see the progress of students in effectively using their time for their objectives.
REFERENCE
[5] G. Dubey, Fundamentals of Electrical Drives, New Delhi: Narosa Publishing House, 2009.
59
[6] Goosen, "P.V. Transformer accessories, (On behalf of Study Committee 12)," p. 12–104,
1996.
[7] X. a. Y. L.Box, "Dyanamical analysis of voltage stability for a simple power system,
Electric Power Energy syst," Vols. vol.23,no-7 ,pp.557-564., 2001.
[8] M.H.Haque, "On-Line monitoring of maximum permissible loading of a Power system
within voltage stability limits," no. EEE Proc. Generaton, Transmission and Distribution.
[9] N.Yorino, A.Funahashi and H.Sasaki, "On reverse control action of on load tap changers,
Electrical power energ syst,"Vol.19,no8, pp. pp.541-548, 1997.
[10] Aklok ," Guide for the Application, Specification, and Testing of Phase-Shifting
Transformers", vol. 1991, no. IEEE.
[11] L. Li, J.Yu and Z. Liu, " Research on parameters drift problems in tracking Thevenin
equivalent," Vol.25, no.20, no. Proc. CSEE, pp. pp.1-5, 2005.
[12] Intelligent control of On- Load Tap changing Transformer. IEEE transactions on smart grid,
vol.5, No.5, September 2014.
[13] Nikunj R. Patel, 2Makrand M. Lokhande, 3Jitendra G. Jamnani Assistant Professor," Solid-
State On Load Tap-Changer for Transformer Using Microcontroller | ISSN: 2321-9939".
[14] M. A. Redfern, "The enhancements to the AVC control scheme using Source Drop
Compensation and pre-emptive tap changing enable the voltage control," no. , IEEE 09, pp.
1-6, 9-11 , 2009.
[15] R. Shuttle worth, B. A. T. Al Zahawi, "mechanical on-load tap changing power transformer
with the use of high-power semiconductor," no. IEEE press, Piscataway, 2002.
[16] Smith C A, Potts S C and Redfern M, "Simulation Studies of OLTC Transformer AVC
relays Operating in Series using a RTDS, Real Time Digital Simulator," 2001.
60
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DEBRE TABOR UNIVERSITY FACULTY OF TECHNOLOGY

DEPARTMENT OF ELECTRICAL AND COMPUTER

ENGINEERING (POWER STREAM)

HOSTING COMPANY: DASHEN BREWERY SHARE COMPANY

INTERNSHIP REPORT AND PROJECT

Submission Date: 29/06/2015 E.C

Student Name: Signature Date

Advisors Name: Signature Date

_______________________ _______ ______

________________________ _______ ______

_________________________ ________ _______

Department Head Name

__________________________ _______ _______

2.3.2 Beer processing section...................................................................................................7

4.2 Solution Proposed.....................................................................................................35

5.3 Recommendation for University..............................................................................58

Figure 4. 9: Tap changer location................................................................................................................45

Table 1.1: The basic difference of draught (draft), bottled beer....................................................................2

Table 4.1: showing arrangement of taps with voltage limit.........................................................................48

Figure 1.1 : Background of Dashen brewery share company

1.2 Main Customers and End Users of the Company

 It gives value for the eco-environment friendly manner.

Figure 1. 2: Organizational structure of Dashen brewery.

1.5 Key Stake Holders of Dashen Brewery Factory

Figure 1. 3: Block diagram of Overall Production process of the company

Figure 2. 1: Overall flows of the product in the packaging room

Figure 2. 2: Depallatizer machine.

It is controlled by electrical device such as;

Figure 2. 3: Uncaser machine.

Figure 2. 4: crate washer machine.

Figure 2. 5: bottle washer.

Figure 2. 6: filler machine

Pasteurizer machine: Pasteurization is the process of killing organisms. The pasteurizer

Figure 2. 7: pasteurizer machine

Figure 2. 8: Labeler machine

Figure 2. 9: Caser machine

Figure 2. 10: Palletizing Machine

Figure 2. 11: Keg machine

2.4 Overall System Components Found in Dashen Brewery Share Company

2.4.2 Components of plc

Figure 2. 12: Major components of Programmable logic controller (PLC)

Figure 2. 13: Input interface module

Figure 2. 14: Output interface module

Figure 2. 15: Operation cycles of PLC

2.5 Input Devices:

2.6.1.1 Synchronous motor

Figure 2. 16: Contactor

2.6.4 Solenoid valve

Figure 2. 17: block diagram of power consumption for Dashen brewery

 Good communication skill

 power transformers are do automatically in the company it is better to design stepper

Keywords: Transformer, microcontroller, voltage sensor, stepper motor.

4.9 Literature Review

4.10.1 Procedure of the study

Figure 4. 1: Methodology flow chart

4.10.2 Project methodology

Figure 4. 2: Block diagram of the system

4.11 Block Diagram Description

Figure 4. 3: power transformer

Figure 4. 4: Circuit diagram and waveform for bridge rectifier

Figure 4. 5: Arduino uno microcontroller

Figure 4. 7: Stepper motor circuit diagram

4.11.1 Operation of stepper motor:

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