DEPARTMENT OF MECHANICAL

ENGINERING
APPARENT SHIP REPORT

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BACKGROUND OF THE COMPANY

Brief history of BGI

• BGI is an international brew company that operates in many countries.
• BGI is the first private owned brewery in Ethiopia, which established in 1998 (GC).
• The factory situated in Northern Ethiopia, Kombolcha Town. More than 15,000,000 USD have invested in 1997 to erect this new modern company in the heart of
the Wollo region. The factory produces three brands beer: Bati, Castle and St. George Amber, Zebidar, Raya, Panash bottled beers. Now only castle and St. George
beers are produce.
• The factory designed to produce 250.000 hectoliter of beer /year. At The beginning there were a total of 143 employees working in the. factory in which 20
employees in fabrication ,23 in bottling , 6 in quality control ,19 in finished goods store, 13 in sales ,23 in maintenance and 39 in administration

Main product or services

 BGI Kombolcha brewery is huge company that produces both beer and draught. Its mean product is beer.
 Additionally, the company gives aid for the society in different social networks; youth involve themselves in the company.
 Generally, the company play important role in:
 supporting and promoting social activities,
 committing with socio-economic problems of the country,
 Training the workers to upgrade them a high level of competence and all the workers show great commitment and devotion to keep the brewery and its
product popular.

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 Customer or end user

• The company aimed to produce quality products to satisfy the needs of customers. Its product is bottled beer and pasteurized draught. From store, the beer is sold to
wholesalers and consumers. Trucks transport the distribution of the product to different regions of the country. The distributions are managed and controlled by the
sales department of the company. Apart from local, the company is also exporting beers to Djibouti and sometimes to USA and Europe. To meet the needs of the
customer since the company product is beer it is distribute to each parts of the country as can as possible. Different societies are its product user. The sales
representative of the company distributes the product fairly to satisfy its customer. Otherwise, the opponent company gets advantages to take its client. Currently BGI
has so many costumers; its product is not keep in store since the produces are familiar.
• Generally main consumer or end users are:
 Wholesalers and consumers in over all the country
 Foreign country such as Djibouti, USA and Europe.

Overall organizational structure and work flow

• The overall organization of BGI is that there is one head office in Addis Ababa, which controls the whole other branches. In each factory general manager is play a great role to
coordinate the work.
 There are also different departments to make the workflow easy and fast. In Kombolcha brewery, there are four departments: -
 Technical departments
 Administration department
 Sales
 Marketing department
 and financial department.
• under maintenance department: • In technical department: - • Under Fabrication department: -
 General workshop  maintenance sub-department,  Brew house
 Electric section  Filtration  Quality control Fabrication
 Utility
 Spare part store  Bottling department  and Raw materials store are included
 and Garage

• Additionally, each department has their own sub-department.

• Kedging and bottling are found in bottling section. Administration department also sub-divided into Administration office, medical service and security guards. In sales and
marketing department: -salesmen, promoter and sales and car drivers are Included. In Finance department: -Accounting and finished Goods are under these departments.

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.

Head Office
Addis Ababa

Technical Administration Sales &Marketing Finance

Departmen Department Section Department
t

Administration
Office Salesmen

Maintenance Bottling Fabrication Accounting Finished

Dep’t Dep’t Dep’t Section Goods Store
Promoters
Medical
Service
General Brew Sales and car Empty
Kegging
Workshop Drivers Store
Section House

Security
Electric Filtration Guards Full
Section Bottling
Section Stores

Utility Quality
Control

Spare Parts
Store Raw Materials •.

Store

Garage

Fig. Organizational structure

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 Safety Rule in the Company
• To prevent accident from happening, the following rules must be considered:
 Work quietly and give full attention the job.
 Keep the tools and equipment under control.
 Do not wear rings, necklace and jewelry.
 No exposed open sores or infected cuts.
 Wash hand any time they become solid.
 Wear safety shoes, glass and hearing protection.

Utility Section
• Under this section
 Boiler plant
 Air compressor
 Ammonia compressor
 Co2 compressor
 and Refrigeration plant are found. 

i. Boiler plant
• Boiler is used to produce steam for utilization of:
 cleaning bottles
 sterilization of beer
 cleaning beer line
 for boiling or heating of malt in brew house.

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 Fig. boilers

 In this company, there are three boilers in different capacity of Steam production rate.
 Two boilers are working in each day alternatively.
• Each boiler use fuel to change water to steam.
• To reduce fuel consumption fresh water should preheat before feed in to boiler.
• To preheat the boiler feed water we use used steam in condensed form to increase the temperature of feed water, which helps to use
the fuel economically.
• The boiler is three-pass fire tubes boiler.
• In addition, it has burner to generate heat energy.
 In this plant, there is a condensate tanker which use to mix treated fresh water and return of used steam in condensed form to pre heat the boiler feed
water. Pre heated water deliver to boiler from condensate tanker with the help of water pump.

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 ii. Air compressor plant

• Compressed air is used in the factory for

 cleaning in workshop,
 blowing of car tire,
 cleaning dust of the machine,
 cleaning of floor and
 use for pneumatic system of Decrater and crater machine.
• The machine which is use to compress air is called compressor.
• Air is compressed in two stages first and second stages.
• Air is from atmosphere and filtered using air filter. This cleaned air delivers to first
stage and second stage. After each stage, compressed air cooled by fan.
• The body of compressor is cooled by oil.
• There is also:-
 integrated dryer
 moisture trap after each stage
 electronic water drain and
 drive motor are found.

Fig. Air compressor

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 iii. CO2 Compressor plant

•• Carbon
• die oxide is the most useful element in beer factory.
 CO is byproduct
2 of starch in fermentation process. The quantity of CO that can be
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collected from one TOD (Tank out Door) is about 3000 kg. Since this compound is used in
beer, filling process its quality should be assured until 99.8 CO 2 is gain .
 So to achieve the quality of CO2 should be treated before compression.
• Foam trappers: - Solid matters are washing with water and removed in the foam trap.
• The scrubbers: - Is to remove water-soluble impurities from the CO 2.
• The Balloon:- Is used to store CO2, evens out the variation in CO2 flow rate and controls the
stopping and starting of the compressor.
• The Drier: - Dries Co2 not to have very saturated humidity.
• Deodorizer: - Remove non water-soluble impurities and it contains an activated carbon bed
through which CO2 passes.
• Liquefaction: - The pure, dried and compressed CO 2 gas is turned in to liquid CO2 by cooling
it down by glycol to below

Fig. Carbon dioxide compressor

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 iv. Refrigeration plant

• In with
• this plant, glycol is firstly cool by water, which its temperature is down to 2
the help of air fan in water cooling tower. Then ammonia is use to cool
glycol to the desire temperature aboutand stored in an insulated tank.
• Glycol use for:-
• This glycol is circulated in the jackets of TOD’s to cool down beer to the
required temperature. The return glycol is again returned to the warm
glycol tank and from this again cools down to be reused again.
• This cold glycol also use in changing gas state of CO2 in to liquid state for
storage.
• Cooling of water that used for wort cooling during casting.

Fig. Oil separator in glycol plant

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V. Water treatment plant

• The sources of water are from the well and its capacity 60 m 3/hr. The water from the well is pumped and stored in raw water tank, which is called raw water.
 The capacity of this tanker is 170m 3.
• Steps in water treatment:
• From raw water tanker the water is pumped to sand filter tank to be filtered mechanically. Water passes layer of sand and store in to filtered water tanker.
 25m3/hr water is filtered from sand tanker.
• Filtered water is pumped to chlorinated water tank, for microbiological treatment and another part water is used for bottle washing and pasteurizer in
bottling.
• Chlorinated water passes through the carbon filter tank to remove the chlorine and then the water will be used for brewing.

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 Executed task

• 
• In four-month internship duration, I have carried so many work tasks. I have done a project to :-
 increase the steam production capacity
 maintenance of air compressor
 maintenance of ammonia compressor
 pumps
 changing of bearing and
 frainshera, checking of engine valve clearance.

1) Boiler
• While steam boiler design they have ultimate steam production rate at specific working pressure, inlet feed water temperature at specific power rating of the
boiler. When we examine the boiler of BGI we found that the maximum steam kg per hour does not produced as the manufacturer of the boiler set. so to achieve
this maximum steam we know that the temperature of feed water to the boiler is not delivered with the required amount .so to overcome this problem we design
heat exchanger and this heat exchanger is use exhaust gas of the boiler which is reach up to 180 to increase the temperature of the boiler feed water up to the
desired value. This is done in condensate tanker.

2) Air compressor

• Here in BGI compressed air is used in garage for tire, in workshop for cleaning chips, it also uses to clean floor. To get this compressed air we use air compressor. Air
which comes from the atmosphere passes through air filter to avoid dust particles. Then air is compressed in first stage and second stage compressor. After each
stage the compressed air is cooled using the help of fun. Therefore the temperature of each stage is set between minimum and maximum range and the result is
displayed on electric bored so the operator can control the output of each stage temperature. One day the electric board display that the output of the second
stage temperature is out of the programmed value. This result implies that there is something wrong happen in some where in the compressor. To over come this
problem we have take action that ,cleaning air filtration ,checking of air fun cooling system of each stage ,changing oil filter cap ,checking of each integrated dryer
of each stage , checking of safety valves, moisture trap and cooling fan. Finally the desired temperature is set to its programmed value.

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3) Pumps
• There are different types of pumps in different size and capacity to deliver fluid from one place to another place. I have changed the bearing of the shaft that
connects the motor and the pump. And also connecting pin was changed

Challenges on work

• The first challenge was even if you want to get involve in to the work soon, since each position has its own assigned person for each task you don’t get the chance
to work. But afterward when the operator knows you and begin to communicate well with him, he let the work to operate yourself.
• There was also communication problem with operators and technicians. Most of the operators run the machine by long time experience and they have no idea
about mechanism of operation of the machine. This makes the way so difficult to get full information about a certain machine.
• The other challenge is to joining and considering yourself as one of the company member. At the beginning everything is guest to accept but gradually it becomes
so simple.
• Wake up in the morning and attend the work and make social network may be a little bit challenging for the first time.
• Some manuals are not written in common language this makes a little challenge to get information about a specific machine.

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Benefits of the internship

A. Improving practical skill

• The curriculum is nice to have skilled man power for our country. When I get the theoretical part in practical it is so interesting to face the real world and by this
internship program I have try to relate the theoretical knowledge with the practical part .So after school when I join the real world I will be effective and I can win
challenges with no trouble.
• I know that it is better to show some thing rather than teaching for some one. Psychologically I am good and I gain confidence how to practice some thing and
how to change ideas in to business. Knowing the atmosphere at work place has great advantage for me. I was sock while the bottle unexpectedly crashed and also
noise of the machine was doesn’t give comfort .Then after all things becomes easy and nothing make me frighten.
• At the beginning even it is not easy to loosen the bolt quickly. But gradually I become experienced and specially working with skilled technicians help to share their
skill.

B. Upgrading theoretical knowledge  

• During internship duration I am not only develop the practical skill but also I recall and relate the theoretical knowledge with practical. While you do something
you force to refer about the subject this make you to remember and upgrade yourself.

C. Improving interpersonal communication skill

• Communication is the processes by which people transmit and exchange information or message. I know that communication is vital, for instance, to enable
employees to do their work and to help people to work harmoniously together towards the achievement of the organization’s goal.
• Trying to understand others opinion and be positive thinker always make people like to work with you and make them willing to share skills and experience what
they know in life.
• I have learned how to work with leaders the interaction between the boss and the worker. In my internship duration I try to know the feeling of operators to their
leaders who treat them in different way. I also learn how to handle people in working place.
• I have not gotten serious communication problem in my internship duration. But I try to understand that always good interpersonal communication skill and making
good deal with people make some one successful at work place.

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D) Improving team playing skill

• Team is any group of people working together to achieve a common goal. People work interdependently amongst the member of the team regarding
resource, information and skill.
• I realize that actively participate in team work has make some body know more and increase personal confidence.
• I know that while working in team trying to create good team sprit always has advantage for success. And Working together to solve problems always
develops friendship and this help to handle problems easily.
• Always be honest and give appreciation to others help someone to have good relationship with them.
• I tried to make good working atmosphere and create good will to make others share their experience.

E) Improving leadership skill

• Now I have awareness that good management always includes the ability to motivate people ,so they are actually inspired to achieve the goals identified by the
leader, a central attribute of good manager is the ability to create an environment in which people are motivated to act in a goal directed way. I know that this can
only done over the long term if manager show concern for the improvement of the life of all customers, the owners, the employees and the community of the
organization.
• In BGI I have seen that all leaders get involve them self in work rather than looking outside while something wrong happen to a certain machine and it become
beyond the operators skill. This teaches me a lot and Good leader should be decision maker, fostering development, flexible, committed, involve himself to work,
solve problems and to reason to learn and to understand.
• Always people like praise and appreciation rather than condemned. So to be a good leader give appreciation for workers to make them effective worker.
• I know that criticizing the other person about his mistake not make him rightful for the next time rather trying to admit his wrong doing smoothly make him
effective not doing it again and encouraging worker for their doing make them to work harder.
• Always trying to share opinion with workers is the key way to achieve the goal and it make your company profitable rather than ordering them to do something and
also approaching your worker friendly always makes the worker trigger, inspire for his work, and be successful.

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F) Work ethics
• I know that a good personality at work place should be disciplined. Be for starting your work first you should know a bout rules and regulations of the company.
• If you do some thing wrong at working place, you will admit your fault. Means be responsible for each action you doing.
• You should respect and tolerate all society of the company.
• Always be punctual and do your work honestly. If you do not be at work on time you upset the working process of the company and also you lose your payment.

G) Entrepreneurship skill
• Entrepreneurs are those who are movers and shakers of the society.
• Entrepreneurship is the process of creative distractions and taking risk individually and independently.
• I have done mini – project on boiler with my friends.
 The project was how to use energy economically.
 Basically the aim of the project was to reduce fuel consumption of a boiler which is used to produce steam.
 This energy is gain from exhaust gas of a boiler to preheat boiler feed water that makes the boiler produce steam with no more fuel consumption.
 By this work I realize that it is possible to create your own business rather than keeping work in government sector. So always be creative and
innovative which make someone successful in a life.

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