Untitled

DIRE DAWA UNIVERSITY INSTITUTE OF TECHNOLOGY
SCHOOL OF ELECTRICAL AND COMPUTER ENGINEERING

INDUSTRIAL CONTROL ENGINEERING CHAIR
HOSTING COMPANY: EAST AFRICA BOTTLING SHARE COMPANY
(EABSC DIRE DAWA PLANT)
DURATION OF INTERNSHIP: November 25, 2022-February 23, 2023
FINAL REPORT AND PROJECT

Prepared by:
NAME ID
1. MERON TESFAHUN 1103091
2. SEID JUHAR 1102513
Advisor Name: Mr. Nurye H. & Mr. Alemayehu T.
SUBMISSION DATE: - 27/06/2015 E.C
Dire Dawa, Ethiopia

INTERNSHIP REPORT AND PROJECT 2023
DECLARATION
We are a 5th-year Electrical and Computer Engineering students at the Dire Dawa Institute of
Technology. And we have undertaken our internship experience in East Africa Bottling Share
Company for three months under the guidance of our supervisor Mr. Dereje Shawl and our adviser
Mr. Nurye Hassen and Mr. Alemayehu T. Finally, we want to let you know that this company is a
good representation of the effort we put into advancing theoretical knowledge's integration with
the actual application. We clarify that our work is original and compiled according to the internship
report writing guideline given by the Institute.
Name of Student Date Signature
1. Seid Juhar ------------- -------------

2. Meron Tesfahun ------------- -----------
ADVISOR’S DECLARATION
As the student academic advisor, I clarify that the internship prepared by the student is original
work and compiled according to the guideline provided by the Institute office as far as our
knowledge is concerned.
Name of Academic Advisor Date Signature
--------------------------------- ---------------------- ---------------

----------------------------------- ------------------------ -----------------
SUPERVISOR DECLARATION
This research project has been submitted for examination with my approval as the Company
supervisor
Name of Company supervisor Date Signature
------------------------- ---------------------- -------------
i |Page
DDIT SCHOOL OF ELECTRICAL AND COMPUTER ENGINEERING
ACKNOWLEDGEMENT
First, we would want to express our gratitude to our almighty, merciful GOD for everything he has
done for us and for enabling us to experience this. Finally, we would like to thank all the East
Africa Bottling Share Company employees for their assistance and explanations in every
department of the business. There were a variety of people that worked with us from the beginning
and during the duration of the internship program. First, we would like to express our gratitude to
Mr. Dereje, an advisor at the EABSC DD plant, for his time and any explanation on Mr. Abdi and
Mr. Yared. Finally, Mr. Nurye H. and Mr. Alemayehu, advisers at Dire Dawa University, have
been our input throughout the Three-month internship program.
ii |Page
EXECUTIVE SUMMARY
In addition to the academic information acquired from the university, the internship program aids
the students in their ability to know and understand machines in the actual world. This internship
report is a written account of our three-month effort to improve our practical skills.
The East Africa Bottling Sharing Company's organizational structure as well as its brief history,
mission, and vision, as well as its primary products and customers, are all discussed in this report.
This internship program has given us many advantages in terms of upgrading our theoretical
knowledge by combining it with the reality found in industries. Those advantages were briefly
discussed in the respective section of this report. The report also discussed the different sections
of the company we have been working in, and the knowledge we gathered in those sections.
We also find a problem that was employee low performance and its effect on productivity generally
the internship has helped us to develop good social and communication skills. We develop
knowledge on how to communicate with different employees (with the engineers, technicians,
team leaders, and workers from other departments). The report has been written according to the
given guidelines and has everything about our internship experience. The following pages will
discuss them all.
iii |Page
Table of Contents
DECLARATION ......................................................................................................................................... i
ACKNOWLEDGEMENT .......................................................................................................................... ii
EXECUTIVE SUMMARY........................................................................................................................ iii
ABBREVIATION ..................................................................................................................................... vii
LIST OF TABLES ...................................................................................................................................... x
PART ONE: INTERNSHIP REPORT ..................................................................................................... 11
CHAPTER ONE ....................................................................................................................................... 11
1.1. Introduction .................................................................................................................................... 11
1.2. History of The Company................................................................................................................ 11
1.3. Vision, Mission and Values of The Company ............................................................................... 12
1.3.1. Vision Of The Company ......................................................................................................... 12
1.3.2. Mission of The Company........................................................................................................ 12
1.3.3. Values of The Company ......................................................................................................... 12
1.4. Main Services of The Company .................................................................................................... 13
1.5. The Main Customers of The Company .......................................................................................... 13
1.6. The Overall Organization and Work Flow .................................................................................... 13
1.6.1. Organization structure of the company ................................................................................... 13
1.6.2. Workflow of the company ...................................................................................................... 14
CHAPTER TWO ...................................................................................................................................... 15
OVERALL INTERNSHIP EXPERIENCE .............................................................................................. 15
2.1. How We Get into The Company ................................................................................................... 15
2.2. The Activities of The Company We Have Been Working On ...................................................... 15
2.2.1. Areas we have been working on ............................................................................................. 15
2.3. Working Flow in Each Section Of The Company ......................................................................... 16
2.3.1. Water Treatment ......................................................................................................................... 16
2.3.2. Waste Water Treatment Plant ................................................................................................. 20
2.3.3. Boiler Room ............................................................................................................................ 24
2.3.4. Chiller unit .............................................................................................................................. 27
2.3.5. Air compressor ........................................................................................................................ 30
iv|Page
2.3.6. Bottle washer machine ............................................................................................................ 31

2.3.7. Blender/Mixer ......................................................................................................................... 33
2.3.8. Filler Machine ......................................................................................................................... 37
2.4. The work task that we have been executing .................................................................................. 36
2.5. The procedures used while performing the work task ................................................................... 38
2.6. How good we have been in performing our work task .................................................................. 38
2.7. The challenges we have been faced during the internship ............................................................. 39
2.8. Measures we have taken to order to overcome the challenges ...................................................... 39
2.9. The design and construction in terms of safety and economy ....................................................... 39
CHAPTER THREE................................................................................................................................... 40
OVERALL INTERNSHIP BENEFIT ...................................................................................................... 40
3.1. In terms of improving practical skills ............................................................................................ 40
3.2. In terms of upgrading our theoretical knowledge .......................................................................... 40
3.3. In terms of improving our interpersonal communication skill ...................................................... 41
3.4. In terms of improving our team work skill ................................................................................... 41
3.5. In terms of improving our leadership skill .................................................................................... 41
3.6. In terms of understanding work ethics and related issues .............................................................. 42
3.7. In terms of improving entrepreneurship skills ............................................................................... 42
PART TWO: INTERNSHIP PROJECT ................................................................................................... 43
Title: Automatic Water Heater Using Solar Thermal Energy................................................................... 43
CHAPTER ONE ....................................................................................................................................... 44
INTRODUCTION .................................................................................................................................... 44
1.1. Background of the project .............................................................................................................. 44
1.2. Statement of the problem and justification .................................................................................... 45
1.3. The objective of the project ........................................................................................................... 45
1.3.1. General objective .................................................................................................................... 45
1.3.2. Specific objective .................................................................................................................... 45
1.4. Significance of the project ............................................................................................................. 46
1.5. Limitation of the project ................................................................................................................ 46
1.6. Scope of the project........................................................................................................................ 46
CHAPTER TWO ...................................................................................................................................... 47
v|Page
LITERATURE REVIEW ......................................................................................................................... 47

2.1. Solar Terminologies ....................................................................................................................... 47
2.2. Solar Thermal Collectors ............................................................................................................... 48
CHAPTER THREE................................................................................................................................... 51
METHODOLOGY TO DO THE PROJECT ............................................................................................ 51
3.1. Overall Methodology ..................................................................................................................... 51
3.2. System Components/ Material Descriptions .................................................................................. 51
CHAPTER FOUR ..................................................................................................................................... 67
4.1. Operation flow chart of the system ................................................................................................ 67
4.2. SYSTEM DESIGN ........................................................................................................................ 69
4.2.1. AutoCAD 3D Design .............................................................................................................. 69
4.2.2. Schematic Design of proteus simulation ................................................................................. 70
4.3 Cost Analysis .................................................................................................................................. 71
CHAPTER FIVE....................................................................................................................................... 74
RESULT AND DISCUSSION ................................................................................................................. 74
5.1. Simulation Result ........................................................................................................................... 74
5.2. Discussions..................................................................................................................................... 79
5.2.1. Controlling System Discussion ............................................................................................... 79
5.2.2 Cost Analysis Discussion ......................................................................................................... 80
CHAPTER SIX ......................................................................................................................................... 81
6.1 Conclusion ...................................................................................................................................... 81
6.2 Recommendation ............................................................................................................................ 81
Reference .................................................................................................................................................. 82
Appendix ................................................................................................................................................... 83
vi|Page
ABBREVIATION
AC Activated Carbon
BSC Balanced Scorecard
BOD Biological Oxygen Demand
COD Chemical Oxygen Demand
CIP Clean Internal Place
DD Dire Dawa
EABSC East Africa Bottling Share Company
EBI Empty Bottle Inspection
EQ Equalization
HFO Heavy Fuel Oil
HR Human Resource
LCD Liquid Crystal Display
PLC Programmed Log Controller
RO Reverse Osmosis
RGB Returnable Glass Bottle
SABCO South Africa Bottling Share Company
SBR Sequencing Batch Reactor
SSR Solid State Relay
SHEQ Safety Health and Environmental Quality
TDS Total Dissolved Solid
TSS Total Soluble Solids
UV Ultra-Violate
vii|Page
LIST OF FIGURES
Figure 1: overall organizational structure .................................................................................... 13
Figure 2: work flow of company.................................................................................................. 14
Figure 3: water treatment plant .................................................................................................... 16
Figure 4: the overall process of water treatment plant ................................................................. 19
Figure 5: grit channel ................................................................................................................... 21
Figure 6: Oil Trapping Channel ................................................................................................... 21
Figure 7: pre-neutralization .......................................................................................................... 22
Figure 8: flow chart of wastewater treatment plant ..................................................................... 23
Figure 9: fire tube boiler .............................................................................................................. 24
Figure 10: flow chart of boiler ..................................................................................................... 27
Figure 11: the process of chiller unit ........................................................................................... 27
Figure 12: Inside process of bottle washer machine .................................................................... 31
Figure 13: flow charts of the blender ........................................................................................... 36
Figure 14: Lifting cylinder ........................................................................................................... 39
Figure 15: filler machine .............................................................................................................. 39
Figure 16: crowner machine ........................................................................................................ 44
Figure 17: packer unpacker machine ........................................................................................... 46
Figure 18: cross-section of flat plate collector ............................................................................. 49
Figure 19: evacuated tube collector ............................................................................................. 50
Figure 20: the methodology of our system .................................................................................. 51
Figure 21: Thermocouple working principle ............................................................................... 52
Figure 22: K-type thermocouple probe ........................................................................................ 53
Figure 23: MAX 31855 Breakout Board ..................................................................................... 54
Figure 24: Dallas (DS18B20) digital temperature sensor interface with Arduino ...................... 54
Figure 25: DC adapter .................................................................................................................. 56
Figure 26: contactor ..................................................................................................................... 56
Figure 27: 1-phase circuit breaker ............................................................................................... 57
Figure 28: Arduino Uno ............................................................................................................... 57
Figure 29: single-channel relay ................................................................................................... 58
viii|Page
Figure 30: 16x4 LCD Display ...................................................................................................... 59

Figure 31: a cross-sectional view of the centrifugal pump .......................................................... 60
Figure 32: evacuated tube solar collector .................................................................................... 61
Figure 33:storage tank (hot well tank) ......................................................................................... 64
Figure 34: heat exchanger ............................................................................................................ 65
Figure 35: Breadboard ................................................................................................................. 65
Figure 36: general block diagram of the system .......................................................................... 68
Figure 37: General operation flowchart of the system ................................................................. 69
Figure 38:3D AutoCAD Design .................................................................................................. 69
Figure 39:Schematic diagram of the system ................................................................................ 70
Figure 40: First step after simulation ........................................................................................... 74
Figure 41: simulation result 1 ...................................................................................................... 75
Figure 44:simulation result in 4 ................................................................................................... 77
ix|Page
LIST OF TABLES
Table 1: quality parameter and standard of water treatment plant ............................................................ 20

Table 2: solar radiation in the Dire Dawa ................................................................................................. 62
Table 3: annual solar radiation in Dire Dawa ........................................................................................... 62
Table 4: Total investment cost .................................................................................................................. 73
x|Page
PART ONE: INTERNSHIP REPORT
CHAPTER ONE
BACKGROUND OF THE COMPANY

1.1. Introduction
Coca-Cola was originated in 1886 by an Atlanta pharmacist, John S. Pemberton (1831–88), at his
Pemberton Chemical Company. His bookkeeper, Frank Robinson, chose the name for the drink and
penned it in the flowing script that became the Coca Cola trademark. Coca-Cola products were first
sold in South Africa in the early 1930s and, in 1938, the company opened its first office in the country.
East Africa Bottling Share Company (EABSC), a subsidiary of CCBA, is the largest bottler of Coca-
Cola products in Ethiopia, having East Africa Bottling Share Company served the country for more
than 60 years.
1.2. History of The Company
(EABSC) is one of the carbonated soft drink beverage coca cola companies in Ethiopia which
produces the Coca-Cola company products. Coca-Cola was first bottled in Ethiopia's capital Addis
Ababa in 1959 by the Ethiopian Bottling Share Company, which later opened a second branch in
Dire Dawa in 1965. The two plants were nationalized in 1975 and ran as public companies until
1996 when they were bought by private investors. Just prior to that, in 1995, the Coco-Cola South
African Beverage Company (Coca-Cola SABCO) bought shares in the business and in 1999 signed
a joint venture agreement with the plants. In 2001, Coca-Cola SABCO increased its shares to 61
percent and the company changed its name to the East African Bottling Share Company. EABSC
continues to run the two plants in Addis Ababa and Dire Dawa. EABSC focuses on bottling and
distributing coca cola products. The company continues to the four branches in Addis Ababa, Dire
Dawa, Bahir Dar and Sebata. In 2011 Coca Cola SABCO again start expanding the business at Dire
Dawa by installing a new bottling line to increase the production volume by 100% and started
production end of February 2012. In 2014, the old lines (Line 1 and Line2) are decommissioned.
Line 1 is upgraded with a new washer and KHS filler and blender from old-line 1. An additional new
line (Line 5) is installed and commissioned in August 2015. Ethiopians enjoy a range of beverages
11|Page
from EABSC, including those from the Schweppes group, Sprite, Fanta, Coca-Cola Coke Light, and
Fanta Strawberry.
1.3. Vision, Mission and Values of The Company
1.3.1. Vision of The Company
To refresh Africa every day and make our continent a better place for all.
1.3.2. Mission of The Company
▪ Consumer relevance by executing a total beverage portfolio across segments and categories
in partnerships with brand owners.
▪ Customer-centric organization delivering sustainable and profitable revenue growth through
outstanding service.
▪ Community/Partner impact by making a difference in sustainability. safety, empowerment,
and local sourcing.
▪ Employee empowerment by mobilizing to execute our plans and transform our system with
agility.
▪ Productivity and responsiveness enabling a continuous improvement culture to create
superior shareholder returns.
1.3.3. Values of The Company
▪ We have a passion for our business, brands, customers, people, and the communities in
which we operate.
▪ We think and act like "owners" at all times.
▪ We work and win in teams across CCBA.
▪ Accountability is clear and personal
▪ We are humble but confident in all we do.
▪ Sustainability and safety underpin our license to trade.
12|Page
1.4. Main Services of The Company
The capability of the company in providing its services increases over time by introducing new
additional brands. The EABSC DD plant provides the following products:
▪ Coca-Cola
▪ Sprite
▪ Fanta
1.5. The Main Customers of The Company
EABSC distributed its product to all over east Ethiopia regions and cities. It includes Dire Dawa city
to Somali, Harar, Oromia, and Afar regions. The customer of the company extends from large trade
organizations to small distributing units then finally, to the consumers.
In those region cities the company has its own main distribution center for:
▪ Restaurants
▪ Hotels
▪ Supermarket
▪ Institutions
1.6. The Overall Organization and Work Flow

1.6.1. Organization structure of the company
Manage
Manufacturing Engineering Quality Logistics
SHEQ
1 Process 1 Electrician 1 Warehouse
2 Utility 2 Mechanical 2 Distribution
3 Production 3 Supervisor 3 Security…
Figure 1: overall organizational structure
13|Page
1.6.2. Workflow of the company
The company first distributer its products to its temporary storage units called OCCD (Official
Coca-Cola Distributer)
Empty glass Full glass ware

Production OCCD
ware house house
Outlet Consumer Outlet

OCCD
Figure 2: work flow of the company
14|Page
CHAPTER TWO
OVERALL INTERNSHIP EXPERIENCE
2.1. How We Get into The Company

In 2022, we joined internship program at East Africa Bottling Company's Dire Dawa facility. The
department head office instructed us to locate the hosting organization for the first semester of the
fifth year. So, we began looking for companies where we could gain valuable experience throughout
our internship program. Then the head office sent a request to the EABSC DD plant among other
industries, and based on our GCPA score of 3 or higher, we were invited for an interview, which
was the biggest experience of our lives. After being welcomed by HR Mr. Amanuel and other
employees, who then gave us safety, wear, and a schedule for the day, we were given a highlight of
the company's history and processes.
2.2. The Activities of The Company We Have Been Working On
Our schedule started on November 25, 2022, and lasted for almost three months. On that day, we
met with the plant trainer, Mr. Dereje Shawol, who gave us a brief orientation about the section of
engineering team sub organizational flow of the section and how we should behave until we finish
our work as planned. He also advised us on what areas we should pay particular attention to.
2.2.1. Areas we have been working on
During our time of internship period, we worked in two sections. Those are:
▪ Utility section
▪ Production and Packaging section
Utility Section
▪ Water treatment
▪ Waste water treatment
▪ Boiler room
▪ Refrigerator Trade service plan and maintenance
▪ Generator
▪ Fleet plan and maintenance
15|Page
▪ CIP room
▪ Laboratory
▪ softener room
Production and Packaging Section
▪ Filler machine
▪ Bottle washer machine
▪ Packer and un-packer machine
▪ Blender machine
2.3. Working Flow in Each Section of The Company
2.3.1. Water Treatment
Since finding clean water in a huge amount is rare, almost all industries consider the water treatment
process to be one of the most critical parts in the production of any desired product. Water treatment
is the process of removing any contaminants and undesirable compounds, reduces hardness from
water and converting it to the suitable and useful for the desired purposes so that water become fit for
it’s the required quality standards. Water is the main raw material and main solvent for most process
in our beverage products.
Figure 3: water treatment plant
Process description of water treatment

a) Bore hole
16|Page
The raw water that is confined underground (beneath around 160m). Raw water from the ground
is pumped and conveyed to the underground storage tank.so this raw water pumps and enters to
reaction tank automatically by level adjustment.
b) Reaction tank
The raw water in the reservoir is sent to the reaction tank which is the first tank in the raw water
treatment plant with the capacity of 100m3.it has cone shape the use being cone shaped for better
reaction process. In this reactor chemicals are added for different purpose.
I. Chlorine (Cl2): - it is used remove (eliminate) any microorganisms such as bacteria and
other microbes.
II. Ferrous sulfate (FeSO4): - Ferrous sulfate is used as a coagulation agent in water treatment.
This means particles become de stabilized and begin to clump together. FeSO4 is dissolved
in the water and then precipitates. While it precipitates, it adheres to other suspended solids
and forms flocks. These tend to settle down since the specific gravity becomes greater than
that of the water.
III. Lime (Ca (OH)2): - is used to reduce the hardness of the water by removing Ca and Mg
ions, which is currently not being used.
c) Sand filter
Sand filter tank is special sand which is used for solid and large particle filtration and reducing
cl amount 1- 3mg/l. The filter needs to be cleaned by an up-flow of water it is called backwash.
d) Buffer tank
Before entering the activated carbon filter tank. It used for reacting the water and reactants
more.
e) Activated carbon filter
In an Activated carbon filter, any organic matters or compounds that cause bad odor or taste
are removed. The treated water from semi treated tank at the bottom is transferred into the
carbon filter in which chlorine is trapped (adsorbed) by carbon. The activated carbon is
removing traces of impurities by the process of adsorption and reduction.
17|Page
Adsorption: -is method for removing dissolved organic substances, particularly those which
cause taste and odor.
Reduction: - is method for removing chlorine and other chemicals that do not adhere to carbon
form water.
f) Micro filtration(polisher)
Microfiltration is type of physical filtration process where contaminated fluid is passed

through a special pore-sized membrane filter to separate microorganisms and suspended
particles from process liquid. This process is done before entering to RO.
g) Reverse osmosis (RO)
Reverse osmosis is a very expensive and sensitive part of this treatment. RO is a water
purification process that uses high pressure for pushing the water through a partially
permeable membrane the separate iron, unwanted molecules, and large particle. The RO plant
consists of membrane layers which operate at 0.001-0.0001micron range this can reject small
ions like sodium and chlorine.
Before entering RO, the parameter must be followed
▪ Pressure >0.4 bar
▪ Temperature <40
▪ PH 4.9-7.5
▪ Chlorine must be zero
The RO plant consists of the following main components, these are
▪ Cartridge filter are used to remove solid and other dirt particles in water
▪ High pressure pump to develop the required pressure
▪ A set of membrane housed in pressure vessels
▪ Piping and valves
We use anti scaling in RO membrane, that used to prevent or slow down the mineral(salt)
formation on the membrane surface.so this chemical protects RO surface from scale
formation.
h) UV light
18|Page
Ultraviolet ray used for purify water. When a water is exposed to UV light which kills the DNA
of bacteria, so it can no longer reproduce and uses to kill harmful microorganism in water. This
UV light used before entering RO, after discharged from RO (before entering treated tank) and
after discharged from treated tank.
i) Treated tank
The main function is to act as reserve container. This treated water used for syrup production,
filer and blender area, Bottle washer, Boiler, and other essential area.
j) RO reject tank
This tank used to store water that does not fulfill the specification. The rejected water used for
shower, carwash etc.
Figure 4: overall process of water treatment plant
Equipment in water treatment plant
▪ PH Meter and flow meter

▪ Pressure gauge and temperature gauge
▪ Butter fly valve, pneumatic valve, and ball valve
▪ Aerator for sand tank CIP
19|Page
Quality parameter and standards of water treatment plant
Check point Parameter Standards

Sand filter out 2p-m +2-+7
let Chlorine 1-3 ppm
Carbon filter PH 6.5-8.5

out let Chlorine Nil
Sensory No odor, no taste, no visible color
After RO PH >4.9
TDS <500mg/l
Turbidity <0.3 NTU
Iron <0.1 mg/l
Conductivity Process requirement
Sulphate <250mg/l
M alkalinity <85 mg/l
Sensory No odor, no taste, no visible color
Table 1: quality parameter and standard of water treatment plant
2.3.2. Waste Water Treatment Plant

▪ Waste water is a water discharged from the company after it has been used for a process. The
behavior of the water depends on the process.
▪ Waste water treatment is a process of treating waste water before discharging from the
company in the way that it will not has impact on the environment.
Source of the waste water and its behavior
▪ In our plant waste water is generated from production room, water treatment plant, CIP
process, cleaning purpose and so on. So, this waste water should be discharged from the
company to the environment, but it has impact on the environment. That is why waste water
treatment was needed before discharging it to environment so that it does not affect the
environment.
20|Page
▪ The waste water has mostly basic behavior due to the usage of caustic soda (NaOH) for
washing bottles. And it also may have oil from lubricants of machine parts and forklift
washing areas.
Waste Water Treatment Plant component and its descriptions
a. Inlet pump pit: The waste water generated from the company is collected in the inlet pump
pit through underground pipes. It will be nearer to the sources of the wastewater because it
serves as the reservoir of all the waste water from the company
b. Grit Channel: This channel is a concrete walled tank in which the waste water treatment starts.
This channel has filtration process using two sieves screen to filter plastics, broken glass and
crowns from passing to the oil trap channel.
Figure 5: grit channel

c. Oil Trapping Channel: The waste water may contain some oil components from lubricants
of machine parts and forklift truck washing areas as well. The main aim of this channel is to
remove the oil from the water.
Figure 6: Oil Trapping Channel

d. Pre-Neutralization tank: Neutralization is the process of treating base with acid or vice versa
to adjust the PH of the water to neutral. In this tank there is PH meter to measure the PH of the
waste water and to dose sulphuric acid (H2SO4) automatically depend on the PH value
21|Page
measured by the PH meter. And there is aerator to provide air so that the dosed sulphuric acid
and the waste water will react easily to make the PH in the operating range.
Figure 7: pre-neutralization
e. Equalization tank (EQ-tank): This tank is a dual-purpose tank which is a final neutralizing
tank and the start-up of biological decomposition of organic waste. This is the starting place
where the organic carbon in the waste is converted in to sludge through microbial activity in
the presence of air provided from the air blower. Here there is dosing of sulphuric acid, ferric
chloride, and urea as per importance
f. SBR1 (sequential batch reactor1): This tank is an aerated biological reactor that convert the
organic carbon to sludge through microbial activity in the presence of air. The bacterium is
first stabilized with the nutrient. After the bacterium is stabilized by feeding the nutrient
biomass of bacteria will be created. The biomass can feed and converting the decomposable
substrate into sludge.
g. SBR2 (sequential batch reactor2): This tank is also an aerated biological reactor working the
same principle as the SBR1 system. The difference is that the unconverted substrate in SB1 is
converted in SBR2. This is the final reaction tank where effluent at the top is discharged to the
environment and the bottom product is pumped to the aerated sludge tank for further
stabilization and stage completion for final discharge. Chlorine will be dosed to kill bacteria
before discharging it and finally the water will be discharged to environment.
h. Sludge tank: This is a tank in which the settled sludge in the tank is collected.
i. Chemical dosing station: is a place where chemicals are stored like sulphuric acid, ferric
chloride, and urea.
j. Chlorine dosing station: is a place where chlorine is stored.
22|Page
Figure 8: flow chart of waste water treatment plant
Waste Water treatment plant Laboratory tests
There are tests that are done in waste water treatment plant process to follow up whether the process
is going well or not. Those are:
1. Power of hydrogen (PH)
2. Dissolved oxygen (DO): is the amount of oxygen dissolved in the waste water for the bacteria.
3. Biochemical oxygen demand (BOD) is the amount of oxygen consumed by bacteria and
micro-organism during the decomposition of the organic material through aerobic process.
23|Page
4. Chemical oxygen demand (COD): is the amount of oxygen required to chemically oxidize the
organic material.
5. Settle able solid: is a test done to determine the amount of solid entering a waste water
treatment plant, as well as to estimate the amount of sludge to be expected during the treatment
process.
6. Ammonia (NH3)
7. Total nitrogen (N2)
Here PH and DO are measured using equipment and the rest are measured using re-agents.
2.3.3. Boiler Room
The boiler is mechanical device used for steam generation it’s one of the essential part of company
where we generate steam energy using inputs like water, air and HFO as a source.
Steam broilers are classified into two:
1. The water tube Boiler and
2. The fire tube Boiler
The fire tube boiler also known as smoke tube Boiler is what the EABSC use to produce steam
energy it is boiler where a hot gas produced by the combustion chamber flow inside the tubes
and water is around the tube which will receive the hot gases heat through conduction process.
Figure 9: fire tube boiler

Some of the components of the boiler are: -
▪ Burner.
▪ The shell side steel part.
▪ The fire tubes
24|Page
▪ Furnaces
▪ tube sheets
▪ Reversal chamber, smoke box and chimney
▪ Air filters and fuel filters
▪ Condensate in feed line.
▪ Screw pump and centrifugal pump.
▪ Level sensor and pressure sensor
▪ safety valves
Beside the above components the boiler also uses inputs like: -
▪ Water condensate from hot will Steam care 610
▪ Heave furnaces oil
▪ Air
BURNER
The boiler’s burner is the component that provides the heat that heats the system’s water. Fuel, air
and heat, must be supplied to the furnace in order to achieve combustion. fuel and air is fed into
the furnace by the burner. A source of ignition is provided by an igniter (an electrode that creates
an electrical arc) the burner contains parts like:
▪ The burner motors
▪ Oil hose connection
▪ The servo motors
▪ Solenoid valve
▪ Photo sensors
▪ Oil filter
▪ Air regulator/Dumper
▪ Oil preheater
Shell: -It is a long cylindrical shell that serves as a pressure vessel. The shell is full of water with
space at the top for steam liberation.
The fire tubes: - pass from one end of the shell to the other they are used to carry the hot gasses for
water boiling.
25|Page
Furnace: - is where combustion occurs it is a place where the highest temperature within the Boiler
is reached.
Tube sheets: -There are the front and back tube sheets which are used to seal both ends of the shell
and a place for mounting of the tubes.
Reversal chamber: -The reversal chamber is used to change the direction of the exhaust gasses as
they exit one pass and are directed into another.
Working principle of fire tube Boiler
Air and fuel are fed into the furnace by a burner. The air/fuel mixture is ignited by an igniter and
treatment plant,
Heat from combustion is transferred immediately to the furnace wall and the surrounding water.
The furnace represents the 1st pass though the boiler (each time exhaust gas passes through the
Boiler, is referred to as a pass). exhaust gasses from combustion then travel to the first reversal
chamber the gasses exit the reversal chamber and then enter the 2nd tube pass, second reversal
chamber,3rd tube pass, smoke box and finally the chimney.
Water is heated by the heat from combustion and the resultant exhaust gasses.as the water in the
shell is heated, steam is liberated at the top of the boiler shell. Steam continues to accumulate until
the desired pressure and temperature are reached.
Shell max boiler
The shell max fire tube boilers designed to generate steam with a high pressure of about 8 bars.
Steam generated in the boiler used for:
▪ Bottle washing
▪ CIP purpose
▪ For CIP. in the production area and For Sugar dissolving in simple syrup
preparation Combustion begins
26|Page
Water Smoke Bottle washer
Boiler CIP process in

HFO Stea the water
Sugar dissolving
Air
in simple syrup
preparation
:
Figure 10: flow chart of boiler
2.3.4. Chiller unit

An industrial chiller is a refrigeration system used to lower the temperature of machinery,
industrial spaces, and process fluids by removing heat from the system and transferring it
elsewhere.
Vapor compression chillers achieve a cooling effect by circulating coolant in pipes through the
processes requiring cooling. The plant chooses to us R134A as a refrigerant. The chiller unit
consists of main components connected to one another by pipes and a cooling tower system. These
are: Evaporator, Compressor, Condenser, Cooling tower, Expansion valve
Figure 11: process of chiller unit
27|Page
Main parts of a Water-cooled chiller unit
Compressor
The compressor is the driving unit of any chiller system.it generates the pressure gradient necessary
to push refrigerant around the chiller unit to achieve process cooling. The refrigerant vapor is
drawn out the evaporator by the compressor. The task of compressor is to compress the refrigerant
to achieve this task the system uses screw type compressor. The refrigerant enters the compressor
as low-pressure low temperature saturated vapor is compressed by the compressor to have a high
pressure and high temperature superheated vapor which goes to condenser.
Condenser
The condenser is a shell and tube-like condenser used to condense the vaporized or heated
refrigerant gas. The water used in the condenser to condense gas is returned to the cooling tower
and get cooled by a forced convection system that uses a high-speed mechanical fan and circulates.
Basically, what the condenser does is it help to remove heat or the high temperature of the
compressed and superheated gas or vapor using the cooled water from the cooling tower and
change the high temperature high pressure refrigerant vapor into high pressure mid temperature
saturated liquid
Centrifugal Pumps
The centrifugal pumps in our chilling unit are used to transport cooling tower water to and from
the condenser and to transport chilled water to and from the reservoir. There are two centrifugal
Ground pumps, which are installed to work in standby.
Cooling tower
It is heat rejection device it is where the heated water from the condensers go to lose the heat
absorbed from the refrigerant gas. The heated water is piped to the cooling tower where it is
“sprayed out” then cooled in the tower as some of it evaporates into the air also passing through
the cooling tower. In the cooling tower, the water mixes and evaporates in the introduced airflow
by fan. Airflow escapes the top of the tower at a more humid condition than when it entered. By
evaporating the water, the remaining water is cooled, and then mixed with a smaller flow of make-
28|Page
up water to maintain the mass flow rate. The cooled water by the cooling tower is pumped back to
the condenser by two pumps. The water that is lost to the evaporation and to mist carry-over will
be replaced with fresh water.
Expansion valve
As the name imply the expansion valve is used to expend the refrigerant gas when the saturated
liquid high pressure which come from the condenser through the expansion value it will be reduced
into low pressure low temperature half liquid half solid (mixture of both) due to the narrow tubs
inside the valve after this the refrigerate return to evaporate.
Evaporator
The chilling system begins in the evaporator it’s place between the expansion valve and the
condensers which remove heat from any associated process into circulating refrigerant.
refrigerating liquid enters the evaporate and absorb latent heat from the chamber at a constant
pressure and comes out as a vapor then the refrigerant gas goes back to the compressor
The working principle of water-cooling chillers
The refrigeration cycle starts with a low-pressure liquid/gas mix entering the evaporator. In the
evaporator, heat from the process water or water/glycol solution boils the refrigerant, which
changes it from a low-pressure liquid to a low-pressure gas. The low-pressure gas enters the
compressor where it is compressed to high-pressure gas. The high-pressure gas enters the
condenser where ambient air or condenser water removes heat to cool it to a high-pressure liquid.
The high-pressure liquid travels to the expansion valve, which controls how much liquid
refrigerant enters the evaporator, thereby beginning the refrigeration cycle again.
The main purpose of chilled water in our plant is,
▪ For cooling of carbonated beverage
▪ Cooling of deaerated water
▪ For cooling of filtered simple syrup
29|Page
2.3.5. Air compressor
An air compressor is mechanical devices used to increase the pressure of gas by reducing its volume.
▪ An air compressor is a pneumatic device that converts power (using an electric motor,
diesel, or gasoline engine, etc.) into potential energy stored in pressurized air (i.e.,
compressed air).
▪ It can collect air from the atmosphere, separate clean air from polluted air, and store the
clean air in a chamber.
▪ CCBI plant uses rotary screw type compressor because they are very efficient and run
nonstop and requires less maintenance.
Working principle and process
All compressors work using a mechanical element that physically reduces the volume air takes up,
compressing it. In a rotary screw compressor, that mechanical component is a pair of screws. These
two screws are meshed and turn continuously. Air enters and is then compressed in the gap between
the screw threads.
The working components of compressors are installed in the following manner:
Air separator: - is a device that removes entrained air (micro bubble) that is moving with the flow
of the fluid.
Air filter: -it contains air adsorbents that can remove odors and gaseous pollutants such as volatile
organic compounds like CCl4.
Air dryer: -s the air in the compressor cools, water vapor condenses into the tanks, pipes, hoses, and
tools that are connected to it.
➢ This moisture affects the equipment that is mentioned.
➢ The air dryer is applicable for moisture removal pump purposes.
Finally, this compressed and extra filtered air used in:
▪ Packer and unpacker machine
▪ Blender/mixer
▪ Filler
▪ Pneumatic valves etc.
30|Page
2.3.6. Bottle washer machine
Bottle washer machine is a machine that is designed to clean and sanitize everything dirt from the
inside and outside of the empty bottles.
The operation of this bottle washer machine is done by using PLC (Programmable Logic Controller)
system. There are different types of sensors which are used as input for this PLC system, these are
▪ Level sensor: is used to detect the level of water.
▪ Step Counter: is used to count number of bottles entering to the machine.
▪ Pressure gauge: is used to measure the amount of pressure.
▪ Temperature gauge: is used to measure the amount of temperature.
▪ Safety sensor (photocell): there are two safety sensor that used to detect and stop if anything
is present in front of the sensor.
▪ Clutch sensor: used to stop the machine if the safety sensor detects anything.
▪ Inductive sensor: is a sensor that used to detect and control speed.
▪ Conductivity sensor: is a sensor that used to control caustic soda level.
▪ Load cell sensor: used to balance the carrier (pocket).
The dirt bottles pass through the following step to be cleaned:
BD1 BD2 BD3
Figure 12: Inside process of bottle washer machine
In feed: through this system the bottles are lifted by the introducer and pushed to the carrier by the
pusher where the bottles will stay in the carrier during all washing process.
31|Page
Pre-wash zone: In this zone the bottles are sprayed both internal and external by means of spraying
jets of water at low pressure. It used us to remove the dirt and liquid that are inside the bottle.
Detergent zone: There are three bottle detergent which are BD1, BD2 and BD3.
Bottle detergent 1 (BD1); Also, could double detergent because it washes the bottles twice.
It uses: Water, Steam (6 bar from the boiler), Hard caustic that levels 2.1 and Temperature
(Preferable if it is 71ºc).
Bottle detergent 2(BD2): uses Water, Steam (6 bar from the boiler), Soft caustic that levels 1.5
and Temperature (68ºc).
Bottle detergent 3(BD3): It uses pure water to remove caustic and any chemicals that remains in
the bottle.
Rinse zone: used for additional purification. It also used to remove the presence of soda and chill
out the main bottle by spraying water through spraying jets into internal and external part of the bottle.
If soda remains in the bottle and passed out from the washer machine it may cause foam during the
filling system. Before the bottle discharged it rinsed with fresh water that comes with 1.5 bar from
water treatment.
Discharge: through the discharging system cleaned bottles are taken out from the carrier and putted
on to the conveyors.
Components of bottle washer machine
▪ Blower rinse: used to reduce bottle temperature and dry the bottle.
▪ Carrier (pocket): used to carry the bottles during all the washing process. It consists four
hundred rows and thirty columns (400x30).
▪ Reducer: there are six reducers in the machine that used to carry and rotate the carrier.
▪ Lubrication pump: There are five lubrication pump which provide grease to lubricate the
machines.
▪ Jet spray: There are fifteen jets spray that sprays at pressure of 2 bar that used to spray the
water and the caustic that used to wash internal and external part of the bottle.
▪ Introducer: used us to take the bottles from the conveyor.
▪ Pusher: used us to take the bottles from the introducer and feed to the carrier (pocket).
Input fluids for the machine
32|Page
1. Water: is necessary for all rinsing of bottle. At discharge, the internal surface of the bottles
has the same chemical and microbiological characteristics as the water of the last rinse.
Therefore, water must be drinkable.
2. Caustic soda: is used to create the detergent solution in the tanks. Soda is necessary for
washing the bottles which eliminates microbiological contamination in combination with the
thermal effect of the high temperatures in the tanks. Caustic temperature must be 60-70 °c.
3. Chlorine: used at the discharge area that used to reduce the smell of the water and used to
kill micro bacteria. This chlorine dosed (1-3ppm) ten times after the carrier circulates fifteen
times.
4. Additive detergent soaks: is a chemical mixed with caustic that used to remove date code
of the bottle and used to increase shininess of the bottle
5. Steam: is mixed with the water to clean the bottle which enters to BD1 and BD2 zone that
come from the boiler room at 6 bars.
2.3.7. Blender/Mixer
A blender is a system for making drinks where the proper amount of fundamental ingredients
(water, syrup, and CO2) is measured and dosed in a continuous electronic process that results in
extremely good product quality (high precision Brix and CO2 Volume values) under all working
situations (steady-state and during transitory phases).
The system consists of a deaerator, a carbonation, a mixer, and a storage tank for the completed
product. We can provide a sufficient cooling capacity plate-type heat exchanger that is installed
externally to the system to regulate the beverage's temperature.
Inputs that trigger the blending process:
▪ Treated water
▪ CO2
▪ Final syrup
The Main components of a blender
1. Base 8. Water pump
33|Page
2. De-aeration column 9. Syrup pump

3. Syrup tank 10. Vacuum pump
4. Storage tank 11. Booster pump
5. Flow exchange panel 12. Heat exchanger
6. Control panel 13. Automatic CIP
7. Electrical cabinet 14. CO2/ Brix monitoring system
De-Aerating water
The tank is horizontal and has sprayers on both ends. De-aeration of water involves increasing the
surface area to remove oxygen or air from entering water since more air/oxygen uses more carbon
dioxide. Using a vacuum pump, the treated water that is being moved from the treated water tank
storage and mixed first is first de-aerated at the de-aerating tank.
The purpose of de-aeration is:
▪ To remove oxygen and dissolved gases from treated water
▪ To prevent the growth of algae due to excess oxygen
▪ To increase the shelf life of the beverage
There are two main ways of de-aerating treated water. These are:
1) CO2 De-Aerator
Before the water enters the deaerator during a CO2 de-aeration, a quantity of CO2 from the feed
line is injected into the water. When CO2 is put into this low-pressure environment, it
spontaneously releases and absorbs a significant amount of the other gases that are dissolved in
the water. Pre-carbonation is provided by the bigger portion of the CO2 that was injected into the
input water remaining dissolved in it.
For this reason, CO2 de-aeration is not suitable for still-product applications, for which vacuum pump
de-aeration is used.
2) Vacuum pump De-Aerator
The de-aeration tank's low pressure is used to remove the dissolved gases from the water. Like the
last instance, a small amount of CO2 may be introduced here; but, because of the low-pressure
34|Page
regime, virtually all of it is removed. Thus, the mixer can only generate still and carbonated
beverages using vacuum pump de-aeration. Additionally, a little amount of CO2 is fed into this
tank in place of air exiting the tank to reduce carbonation.
Heat Exchanger
The use of pipes or other containment vessels to heat or cool one fluid by transferring heat between
it and another fluid is known as a heat exchanger. A plate and frame heat exchanger is used by
EABSC Dire Dawa Plant to cool the beverage.
Inputs that are used in the heat exchangers are: -
▪ Carbonated treated water that is going to be chill.
▪ Chilled (cooled) water from the chiller room it’s a temperature between 5 and 7’s
▪ Final syrup
The output of the heat exchanger is: -
▪ Cool carbonated water and final syrup
▪ Discharging of chilling water to chiller room (temperature 8 to 10 0c)
Carbonation
Carbonation is the process of combining carbon dioxide with treated water that has been deaerated
and the finished syrup under intense pressure. The final syrup is refrigerated or cooled using a
plate and frame heat exchanger to a lower temperature before adding and blending CO2, which
increases the CO2's solubility in the beverage. The reasons why CO2 is preferred for carbonation
are as follows:
▪ The solubility is easily varied by adjusting the temperature and pressure.
▪ Easily dissolvable in water
▪ It produces carbonic acid in the water, which lowers pH and makes it difficult for microbes
to grow.
▪ It has a preservative effect
▪ It is not toxic/ harmful
▪ It produces pleasantly sparkling effects
35|Page
Blender the location where the final syrup, de-aerated/carbonated water, and CO2 are combined
in the production process. The re-circulation pump receives this cold solution and mixes it with
carbon dioxide at 12-bar in the venture tube. Water, final syrup, and carbon dioxide are mixed
inline and stored in a buffer tank. The carbonated water and the final syrup are first
proportionated. This proportion is different for the different types of beverages going to be filled.
For Coca-Cola, the proportion ratio for blending is 5.4: 1. This means that for 1 volume of final
syrup, there would be 5.4 volume of carbonated water is needed. Then the total volume of
beverages becomes 6.4 volume. In this section, a beverage analyzer is installed to measure the
Brix content of the beverage. Finally, the beverage is sent to filler.
36|Page
Treated water, CO2, final
Blending/ mixing
Sampling & testing
Is the
Adjustment
Brix, ok?
NO
YES
Transfer the product to the

filler
Filling & crowning
Sampling & testing
Brix & CO2, Adjustment

ok?
YES NO
Continue the production & monitor the process
Finished
Figure 13: flow charts of the blender
2.3.8. Filler Machine
Filler is the machine which is the back bone for the company with a lot of interesting modern science
used for filling the present bottle.
37|Page
▪ Filler is one of the most main critical and important machines in this company that enable
the company to produce 36000 bottle (1500 crates) per hours at effective operating
condition.
▪ Bottle came after pass all criteria from EBI and it enter to filler by infeed conveyor. Then
the filler fill step by step.
▪ Filler process cover EBI up to FBI.
▪ Its main product supply is from blender station there are inputs from the blending unit
which are finale beverage (finale syrup and carbonated water) and CO2.
Main Part of filler
1. Bottle handling system: it handles the bottle and infeed to the filler bowel.
▪ Warm screw: its spring shape hardest plastic. Its garden and control the inlet bottle which
get to the in-feed star. Sprite and Fanta use the same warm screw. Coca use different warm
screw.
▪ In feed star: it’s like a road which take the bottle from warm screw and send to filler bowl.
▪ Filler bowl: it has 96 filling valve and each valve have ventube. It receives the bottle from
infeed star and fill each of them step by step. After fill send to middle star.
▪ Middle star: after taking the filled bottle from filler bowl send to crowner star. Coca and
Sprite have the same middle star. Fanta use different middle star.
▪ Crowner star: after receiving from middle star and giving to capping machine after
crowned the bottle give to discharge. Coca, sprite, and Fanta have different crowner star.
▪ Discharge star: receive the bottle from crowner star and outlet from filler room.
2. Ventube: its pen shape tube its piping conducting air ejected from the bottle. It uses for correct the
flow of beverage Coca and sprite have the same ventube. Fanta uses different.
3. Opener (command opener spread): it opens the valve and it uses a mechanical system to open
and close the valve.
4. Spreader: it helps as to get rid of shower the beverage because of this the ability to reduce the
explosion of the bottle.
5. Lifting cylinder: they are a bottle holder .it holds the bottle tightly. The jack support and pushes
the bottle against the filling valve during the filling cycle.
38|Page
Figure 14: Lifting cylinder

6. Bell: its jump up and give to mouth peace and it connect with bottle mouse peace. If it is overload
linkage will be created.
7. Mouth piece: it holds bottle mouse upper part. Linkage is created when the bottle is covered
8. Cam: its black metal though this the air coming out of the Ventube comes out through pressurized
air comes out and control this process. if there is air, it will blow.
9. Center in feed column: this supplies the carouse with the product, CO2, compressed air for the
pneumatic valves and the lifting unites
10. Drive Base; include all the transmission component which drive the bottle conveyor and
handling star wheels the capping units and all machine
Figure 15: filler machine
Filling process
There are seven major processes (step) in filling process
1. Positioning:
The bottle is risen by lifting jacks and positioned with its top in the centering cup under the filling
valve spout.
39|Page
2. Pre-evacuation:
Command presses pushbutton so doing the vacuum room relates to the bottle and the air is sucked.
3. Pressurization
Command centers in contact with the opening command and opens the pressure valve causing the
CO2 to flow into the bottle; another command acts on opening command which sets the valve in
an intermediate position.
4 Filling:
Once pressure in the bowl is equal to one in the bottle, product valve (1) is automatically opened
by the pressure acting on it; Isobar metric gravity filling begins; product, forced onto bottle walls,
flows with the minimum turbulence and so minimum.
5. Filling end:
Filling ends when product gets the lower edge of the air return tube interrupting the CO2 return to
the filler bowl CO2 entrapped in the bottle’s neck acts on the product valve and closes it by a
stronger pressure.
6. Closure and decompression:
Command presses pushbutton allowing gas entrapped into the bottle’s neck to flow into room; in
order to prevent foaming, command 4 engages opening command which closes pressurization
valve and product valve.
7. BOTTLE BURST CASE
In case of bottle burst/crashing, pressurization valve and product valve automatically close so
interrupting gas and product flow.
The centering cup support unit moves downwards and its position is detected by a sensor allowing
the filling valve in washing mode.
SANITIZATION
The sanitization phase can be started from startup and clean after bottle burst case. It is the cleaning
and disinfection of an area or an item it is the act or process of making something completely clean
and free from bacteria. It is important because the quality parameter of the product should remain
constant for very long time it must possible to clean all part of filler. For this purpose, rinsing cups
(half cups) are placed under the filling valve and the cleaning and disinfectant solution are
circulated by pumping through chambers and pipes.
40|Page
Change over
It performs if there is any flavor change or product change.
It performs two processes
▪ Warm rinse and
▪ Cold rinse
Objective of CIP (sanitization)
CIP stand for clean in place

1. To clean the filler machine. Because this machine fills products with sugar product their
deposit, organic and (morphemic salt, oils which are scaled on machine and are not able to
clean by human power can be cleaned)
2. To disinfect the machine from CO2 microbe
At this plant CIP process done every 48 hour and there are two type of CIP process
➢ 5 steps perform every 48 hours (2days) when there is flavor change or not it is done per 48
hours. use for both sanitization and disinfection
Step 1: - Normal rinse
Step 2: - Rinse with hot caustic
Step 3: - Flashing the caustic
Step 4: - Rinse with hot water
Step 5: - Rinse with pure water
➢ 3 steps perform there when there is any product change each other (coke to coke product)
only use for disinfection purpose. But now we don’t use 3 steps at all.
Step 1:- Normal rinse
Step 2:- Rinse with hot water
Step 3:- Normal rinse
Major sensor in filling system
1. Opener sensor: - enable the valve to open and close to fill the bottle or it send a signal to the
system to open the filling valve. It controls the filling process.
41|Page
It is a black wire, that used to give a command to open the command opener if there is bottle come
up with lifting cylinder then read and checked by the opener sensor after that opener change its
direction to downward (downing of opener) to start filling through filling valve.
2. CIP sensor: - used to control the CIP process at the time of CIP step procedure to be operated.
CIP means cleaning in place that means cleaning the whole machine. It cleans:
▪ Pipe
▪ Ventube and
▪ Clean all line of filling system
3. Level sensor: - used for knowing the amount of liquid in the tank filler bowel. Also used to
control the level of all beverage or drink (products) in the tank.
There are 4(four) level sensor in filler bowel and one level sensor in crowner tank.
4. Pressure sensor: -used to measure the pressure of the system (filling system)
Used for determine amount of pressure in whole system. And there is also a pressure gauge.
5. Temperature sensor: - used to measure the total temperature of the filler room.
6. Bottle burst sensor: - used to sense the burst bottle at the time of burst and send a signal to the
filler not fill 5 (bottle) before and after the burst bottle to secure any contamination.
7. Crowner sensor: - used to check and sense the presence of crown to send to crowner machine
or for capping unit.
8. Optical sensor: - check the crown, when the crown does not come to crowner machine it tells
to the filler to stop filling or filler stop because the absence of crown.
9. Proximity sensor: - it divided in two types it detects the nearness of the object.
10 Encoder: - is a sensing device that provide feedback .it convert motion to electrical signal that
can be read by some type of control device system such as counter or PLC. Encoder sends a
feedback /signal that can be used to determine position, count, speed, or direction of the
machine which mean it control the speed of the filler in our case.
Sensors out of filler room (before and after the filler room)
Photocell sensor: - it has a reflector, by using its reflector it detects or check the bottle is fallen or
not. It checks whether there is bottle present or not and send feedback to the filler. And, it adjusts
the speed of conveyor motor by seeing the gap between the bottles.
42|Page
There are two photocell sensors before entering to filler found on in feed conveyor.
Sensors after filler room
▪ Metal detector
▪ Counter sensor
▪ Date coder
▪ Ink
▪ Makeup
▪ Dryer
Dead line (shelf life) of the three products
Fanta =270 days; Coca =364 days; Sprite=273 days
Principle of filling valve
The filling valve is made up of four, easily separated parts:

Filling valve body
The decompression and sanitization push−button valves, as well as the decompression nozzle, are
fitted on to the filling valve body.
Internal unit
The internal unit is made up of the product supply valve and the pressurization valve.
Support column unit
The support column unit also includes the centering cup.
Opening command unit
The opening command unit comprises the support, the command.
Capping unit
▪ The main work is done crowner machine that capping the filled bottle it performs
mechanical closing (capping)system.
▪ At one cycle it capped 18 bottles
▪ This process includes crowner machine up to crowner capping. crowner outlet from
the crowner tank and using lift and sent to crewing to crowned.
▪ The lower rotating part supports the cylinders and transmits the motion
▪ The fixed part encloses in the lower area a thrust bearing and the lifting unit which is
connected to the upper part
43|Page
Proximity sensor: -place in crowner to check whether there is crowner or not.

Capacitive sensor used to detect metal and non-metal and
inductive sensor is used to detect metals
Figure 16: crowner machine

Bottle filling
The bottle filling cycle is divided into three stages:
▪ Empty bottle in feed
▪ Filling
▪ Capping
2.3.9 Packer and un packer machine
Packer Machine: - is a machine which is intended to pick up the filled bottle from the conveyor
to the empty crate.
Unpacker Machine: - is a machine which intended to pick up empty bottle from the crate to the
conveyor.
The main component of the packer and unpacker machine
1. Bottle presence sensor: - used to monitor the presence of bottle.

2. Gripper head: - used to pick up the bottle from the crate.
3. Arm: - is a movable machine which holds the gripper head.
4. Front stopper: - found in crate conveyor, it stops the in-feed crate.
5. Crate sensor: - used to check the presence of crate.
6. Safety Head photocell: - used to monitor the vertical movement of the head.
7. Centering device: - used to keep the entered crate in the right position.
44|Page
8. Bottle guide: - used to guide the bottle for the gripper to be able to pick up the bottles.
9. Crate change detector: - it is 2 in number to detect if newly create are replaced.
10. In feed crate presence: - check if there is in feed crate.
11. Bottle fall detection: - a sensor which stops the machine if bottle falls under the conveyor.
12. Door safety limit switch: - there find 4 DSLS which stop the operation while the door
opening.
Operation of the machine
The machine is designed for filling crates with bottle or cans. The unpacking or packing area in
Numbers equal to the number of grippers head and are positioned exactly under these. The bottles
are picked up by means of heads provided with gripper and mounted on a beam which moves
alternately to complete semi-circular path. in case of packer washed crate in feed to the guarded
area then the front stopper stops after checking there are 5 crates entered then the centering device
catch it for the next step. The arm has gripper which has membrane inside. To pick up the filled
bottle the membrane filled with air(2bar) so it catches the bottle then picks it up and loaded to the
crate. After crate change detector check if new crates replaced by filled crate, then the next step
mentioned above will be perform again. and in case of unpacker cases filled with empty bottle fed
on a conveyor the machine picks up the empty bottle from the crate to the conveyor and here there
is bottle release sensor which make sure whether the gripper return unreleased bottle to the
conveyor before it goes back to unpack the bottle from the crate.
The servo-operated transfer head smoothly and efficiently carries with no drop and keeps them
under control during operation.
45|Page
Figure 17: packer unpacker machine

There are 3 motor drivers
▪ Main drive motor
▪ Crate conveyor
▪ Bottle conveyor
The machine works using shaft encoder which is electro-mechanical device that converts the
angular position of shaft or axel to analog or digital output signal but in Coca Cola Company it
used to convert to digital output.
▪ In packer machine the arm picks at 358° and release at 170° but because of fault if
the machine stops it will stop at 320°.
▪ In unpacker the Arm picks up the bottle at 170°and release at 320°.
Generally, the overall working steps are listed below
A. It is positioned on the containers present inside the crates.
B. It is then lowered to pick up the containers by means of the grippers.
C. It rises, lifting the containers.
D. It moves to the unloading convector.
E. It descends to deposit the container on the conveyor.
F. the grippers slacken their grip and the beam rises leaving the containers which start
coming
G. Out while the empty crates are carried out.
46|Page
Operation modes
There are three modes of operation:

1. Automatic operation: - in this operation the operator has only the task of observing
the fault everything is operated by the machine.
2. Manual operation: - in this operation the machine operates its work by following the
command of the operator.
3. Semi manual operation: - in this operation the machine can be made to perform certain
function automatically and the rest function will perform by the operator.
Alarms and warnings during operation
▪ Fixed green light all the machine section is ready to run.

▪ Flashing green light at least one machine section is ready to run.
▪ Fixed red light the machine has at least one critical alarm condition.
▪ Siren continual a start button is being pressed with the machine ready to run.
▪ Siren intermittent a start button is being pressed with the machine not ready to run.
2.4. The work task that we have been executing
In addition to visiting the overall production process we were on the following tasks
▪ Quality checking for under fill (filling below the standard level), over fill (filling
above the standard level), uncrowning and not date coded bottles.
▪ Operate on pack and un-pack machine, filler machine, washer machine.
▪ We were participating on the palletizing process for the packed product.
▪ We were participating in changing star wheel and vent tube for changeover of
production and semi cups for CIP process.
▪ We participated on CIP day; we clean with the co-worker.
▪ We participated on maintenance at production room, forklift maintenance, cooler
maintenance boiler maintenance and other maintenance process.
36|Page
2.5. The procedures used while performing the work task

During our internship program, it was easy to gain any accesses that help us collect information of
any machine. Here are some of them:
By direct interview:
It was the first choice to gather information by direct interviewing of the operators of the machine
and other concerned people. Operators are the owner of the machine, so that is better to ask him to
know more.
Participating in maintenance activity
During maintenance, machines are disassembled. This situation was very important for us to observe
and make it practical the components of the machine.
Data gathering
It is possible to read the manual of every machine that describes the safety and operation of the
machine which is available in the company’s library.
Other than this we follow
▪ Safety comes first principle and starting a work at a specified time ➢ Do every activity
based on factory manual.
▪ Consulting operators when challenges occur.
▪ Be humble and work in team
2.6. How good we have been in performing our work task

We were always obeying the company’s rules and regulation. We attended full office time hours
Monday to Friday so that we have managed ourselves efficiently to accomplish our internship
schedule on time.as we were so active and encouraged to learn new things, we were engaged in
different works cooperating with the company’s operators facing problems and being able to fix
38|Page
them as the company’s team do. During the last month we studied and figured some problems that
affect the company and we were able to provide solution for it.
2.7. The challenges we have been faced during the internship
Since we were new for the company, we were facing some challenges like:
▪ Coping up with the working condition of factories such as noise of the machine.
▪ Fear to start conversation with the employees until we become familiar.
▪ Because we work the whole day, we were unable to get free time to develop our
knowledge, search more and do our project.
▪ Shortage of locker to put our working uniforms (PPE).
▪ There was no place to refresh during the spare part.
2.8. Measures we have taken to order to overcome the challenges
▪ We wear our ear plugs properly so that it cannot bring any damage to our ear and adapt
the environment through time.
▪ We increased our sociability and overcome our fear to freely ask whatever we want and
We used our night times to do our projects.
2.9. The design and construction in terms of safety and economy
The company is well organized and gives priority to safety of employees working under it. The
plants are structured in a safer and profitable way. The different signs in the compound give
information and warn any hazardous condition. There is assembly place to gather and alarm all over
the place if fire starts and these kind of features makes employees feel safe and work attentively.
39|Page
CHAPTER THREE
OVERALL INTERNSHIP BENEFIT
3.1. In terms of improving practical skills
Internship strengthen and expand knowledge relevant to academic background. We have observed
that the theoretical and the academic knowledge must be supported by its practical skill to give a
meaning and we understand a lot of things through the practical skill and experience. The basic
thing that we know during our internship program by their practical application of different
integrated PLC (Programmable logic Control) system different pneumatic cylinder, shaft encoder,
water pump, electro mechanic valve, different motor drive and application and working principle
of pneumatic and hydraulic system. And, we chance to see different type of sensor actuator with
their different function and purpose.
In addition, as electrical engineer we observe the power and electrical installation and also we see
power transmission area generator different type of transformer different type of electrical wiring
and electrical connection. We get knowledge about the maintenance mechanism of some electrical
and mechanical breakdown.
3.2. In terms of upgrading our theoretical knowledge
Internships are a great way to connect classroom knowledge to real-world experience. Learning is
one thing, but taking those skills into the workforce and applying them is a great way to explore
different career paths and specializations that suit individual interests.so this internship program
helped us in many different ways like Specially, we gained detail and clear way of knowledge and
experience in the production of coca cola beverages, in that what type of material is used, how
much energy is used per day and at what temperature and pressure is the process held on as well
as how different machines operate and how management systems work and quality control
mechanisms in the factory.
40|Page
3.3. In terms of improving our interpersonal communication skill
Communication is a basic skill in life to transform our self in all aspects. As we could able to
understood from industrial internship time, out of the key points that makes someone successful in
work 90% is communication, 5% knowledge & the remaining 5% is work experience. We got an
amazing fact that how hard you work depends on how smartly you communicate.
3.4. In terms of improving our team work skill
During our time at EABSC, we learned that team work is the most important in order to improve
▪ Listening skill
▪ Communication skill
▪ Being confidential each other
▪ Developing problem-solving ideas
▪ Supporting each other
▪ Skill of expressing idea
▪ Skill of being able to ask for things that are not clear
▪ Skill of compassioning
3.5. In terms of improving our leadership skill
Being a leader means simply being the most influential person, having better knowledge, being
open-minded & honest for co-workers rather than nominated by somebody & hold power to
suppress others. So, we have learned that during our intern stay in EABSC to improve this
leadership skills we should:
▪ Develop self confidence
▪ Develop communication skill
▪ Eliminates excess fear and doubt.
▪ Develop understanding of ethics and values
▪ Develop a powerful vision
▪ Be responsible and respectful for the co-workers
▪ Be listener and strategic
41|Page
3.6. In terms of understanding work ethics and related issues
In our stay in the company, we learned to perform various tasks in a systematic manner, working
smart which is doing in most efficient way so by valuing work ethics in the company we were able
to develop:
▪ Punctuality
▪ Impartiality
▪ Integrity
▪ Responsibility
▪ Being committed
▪ Finishing work on time
▪ Doing what the boss orders
▪ Do not underestimate people’s thoughts instead respect and encourage them to do better
▪ Focusing primarily on work related issues
▪ Being confidential and self-motivated to do tasks responsibly
3.7. In terms of improving entrepreneurship skills
Entrepreneurs play a vital role in empowering the economy. The entrepreneurship and internship
are always interlinked. Internship Programs are one of preferred activity to improve the
entrepreneurs. Every Person who has an idea cannot become an entrepreneur. In addition, he/she
should be expected to have some practical skills and ability to become an entrepreneur. So, this
internship program helped us:
▪ To develop new ways of thinking, by present large amount of information
▪ New techniques to anticipate and handle risk
▪ Motivation and networking with professionals
42|Page
PART TWO: INTERNSHIP PROJECT
Title: Automatic Water Heater Using Solar Thermal Energy
Summary of the project

New technologies are being developed to optimize energy from all sources due to the rise in the
price of heavy fuel oil and environmental concerns. Because our country is one of those that utilize
fuel oil for several purposes, we must consider other solutions for lowering or replacing our
dependence on it. The price of fuel oil (HFO) is currently out of control throughout the entire world.
The EABSC Dire Dawa Plant uses a substantial amount of fuel oil for steam generation. The aim
of this project is to design and develop an efficient and reliable solar water heater system. The
proposed system is expected to be cost-effective and environmentally friendly. This system will
make use of solar thermal energy to heat the water by using evacuated tube collectors in order to
give hot input water to the boiler. We design and develop Arduino based controller to control
our systems automatically, temperature sensors will be used to measure the temperature of the water
and solar collector, and level sensor used to measure the level of water in the tank. Circulation
Pumps will be used for the transportation of heat exchanging fluid from the storage tank to the
collector. The design of this project has been developed in Auto CAD software and simulated and
manipulated in Proteus software. Overall, this project work demonstrates a method of designing a
solar water heating system with thermal storage that can provide hot water for a boiler machine. An
overview of this work is to reduce the use of HFO and save money as well as reduce the emissions
of greenhouse gas in the atmosphere.
Key Words: East Africa Bottling Share Company, Arduino Uno, evacuated tube collector,
HFO, solar water heating system.
43|Page
CHAPTER ONE
INTRODUCTION
1.1. Background of the project
Energy is an important factor in a nation's development, as it can serve as an engine for economic
expansion. Most human activities in the modern world rely on conventional energy sources, such
as heating, cooling, cooking, and transportation [11]. Solar energy is the best renewable energy
source, as it provides the earth with millions of watts of energy every day, but only a little of it is
used by the natural world. Solar energy can be harnessed in a variety of ways, such as photovoltaic,
solar thermal, solar cooling-heating, and photosynthetic systems. It is free to use, but there are
difficulties in its efficient collection and storage. Burning fossil fuels is a major contributor to global
warming, and the quantity of energy needed by businesses and homes to produce hot water is
enormous and costly [10]. Solar power is the best solution to this issue, as it doesn't release harmful
emissions into the atmosphere.
Solar energy is an efficient way to save energy and money, as well as reduce greenhouse gas
emissions. Solar thermal collectors are the most common parts used to gather radiation that is later
converted to thermal energy and delivered to a working fluid. Solar thermal energy systems are
frequently chosen due to their high energy conversion efficiency [9]. They can be stationary, sun
tracking, or concentrating. Fixed-type collectors include flat-plate, compound parabolic, and
evacuated tubes, while sun-tracking reflectors are used for high-temperature applications like power
generation.
In our project, a solar water heater with evacuated tubes is created to produce hot water at
temperatures ranging from 60 to 80 degrees Celsius to feed boiler machine. This system features a
pump to circulate water through the solar collector from the storage tank, and a temperature sensor
can be in the storage tank and in the collector managed by a microcontroller (Arduino Uno). The
sensor measures the water level, temperature in the tank, and the solar collector. The circulation
pump pumps water through the system so that it can absorb heat from the solar collector and it
works when the tank temperature less than 800c, and the collector temperature is higher than the
water temperature in the tank and there is enough water in the tank. The level sensor put in the tank
that controls the inlet water pump by detecting the level of water in the tank to protect overflow and
dry run. Generally, our project uses two temperature sensors to detect the temperature of water in
44|Page
the tank and in the solar collector, level sensor to detect the level of water as an input and Arduino
Uno as a controlling unit and circulating pump to pump heat exchanging fluid from the tank to the
collector and water pump to pump inlet water in to the tank as output unit.
1.2. Statement of the problem and justification
The price of fuel oil (HFO) is currently out of control throughout the entire world, and because our
nation is one of those that consumes fuel oil for a variety of different reasons, we must look at other
options for reducing or replacing our dependence on it. Steam generation in the boiler is the primary
component of the EABSC Dire Dawa Plant which consumes a significant amount of fuel oil.
According to the company's HFO consumption records, the maximum HFO consumption between
December 1, 2022, and February 22, 2023, was 1487 liters/day when measured using an analog
flow meter [7]. Company use water from the water treatment plant or softener plant, which has a
low temperature (around 300C), and we use water to return from the system during this process. It
can increase the consumption of fuel oil, and decrease the productivity of the machine, and reduce
the lifespan of the boiler by increasing its time to make steam and create a thermal shock.
Our project focuses on to maintain the inlet water temperature to 800c before entering to the
boiler(plant), lowering the fuel consumption of the boiler, which in turn reduces the time needed to
produce steam. It also enables us to lower the occurrence of thermal shock in the boiler by pre-
heating the water using solar thermal energy, which is a clean, reliable source of energy.
1.3. The objective of the project

1.3.1. General objective
The general objective of this project is to design and develop (implement) an automatic solar water
heater.
1.3.2. Specific objective
The following is a list of this project's specific goals:
▪ To develop, and design a forced, circulation solar water heating system to provide hot water
for the boiler machine
▪ Analysis of the existing system
▪ To develop codes to the microcontroller
45|Page
▪ simulate and manipulate in proteus software

▪ To model 3D in AutoCAD Software
▪ To perform cost estimation and analyze pay-back cost of our system
1.4. Significance of the project
▪ Our project which is automatic solar water heater use in a way that is important for our
company or our plant to minimize cost by reducing the usage of (HFO) fuel oil.
▪ Reducing the amount of time needed to boil water and increase the production of steam
▪ Reduce the occurrence of thermal shock in the boiler.
▪ Implement and utilize renewable energy within the international organization
▪ Create a good image for the company by contributing to the reduction of greenhouse gas.
▪ Reduce the emission of greenhouse gas into the atmosphere
▪ Extending the boiler's lifespan and improving its efficiency
1.5. Limitation of the project
Our system depends on the amount of solar radiation, and didn’t have a tracking mechanism. This
affects the efficiency of solar collector to absorb radiation. Initial investment costs amount is high,
it’s difficult to install by individual, we consider only solve our company problem by drawing a
solving mechanism.
1.6. Scope of the project
This project's goal is to create an autonomous water heating system that uses solar thermal energy
and control using an Arduino Uno microcontroller. We employ an Arduino Uno, a relay, level and
temperature sensors, an LCD display, a circulatory pump, and valves. We place the greatest focus
on cost analysis, controlling mechanism, design in AutoCAD, and simulation using the proteus
software. Hence, we simulate the regulating mechanism and determine the system's payback
period.
46|Page
CHAPTER TWO
LITERATURE REVIEW
This section's goal is to review some published literature on various water heating system types.
This area discusses solar water heating systems, including their benefits, drawbacks, how they
differ from other water heating systems, and the system's many heats collector, storage, and
controller configurations.
2.1. Solar Terminologies
Soteris A. Kalogirou discusses the various solar thermal collector types and their uses, such as flat-
plate, compound parabolic, evacuated tube, parabolic trough, Fresnel lens, parabolic dish, and
heliostat field collectors. The solar collectors are instrumented and developed into a test rig to
conduct experimental work, with a capacity of 100 liters/day for household, commercial, and
industrial applications [2]. Data was gathered for both the fixed and tracked states of the flat plate
collector during experiments that lasted for a week with nearly uniform atmospheric conditions.
The findings indicate that the output temperature has increased by an average of 400C, and the
purposes have increased by 21%. These include solar water heating, space heating and cooling,
refrigeration, industrial process heat, desalination, thermal power systems, solar fluorescence, and
solar thermal power system. [1] estimated the techno-economic viability of SWH technologies for
domestic purpose for different types of collectors using RET Screen software for different climatic
conditions in KSA. They found that evacuated tubes solar collectors are better than flat plat
collector with respect to solar fraction, higher energy saving, and GHG reduction. Theoretical and
experimental analysis on the transient behaviors of combined SWH with heat pipes and
thermoelectric power generation system. They observed that, for a typical house with 5 m2 of
available surface area 300 litter of water can be heated to 760C during the peak sun hours.
Samara Sadrin et al can provide different approaches to solar water heating. If the solar water
heater can supply hot water above a predetermined temperature, this automated system would
enable the user to use the solar water heater to obtain hot water [5]. Only the electric water heater
will operate if the solar water heater is unable to heat the water to the desired temperature. It is
effective because our controller makes sure that
47|Page
the solar water heater is utilized to provide hot water 80% of the time and the electric water heater
will provide the remaining 20%. Our method uses solar energy, which is inexpensive and plentiful.
It consumes a very tiny quantity of electricity, lowering costs for the user.
P. Rhushi Prasad et al compare the performance of a flat plate collector in an experiment to that of
a tracking collector. To carry out the experimental work, a flat plate water heater that is
commercially available and has a capacity of 100 liters/day is instrumented and converted into a
test rig. Data was gathered for both the fixed and tracked states of the flat plate collector during
experiments that lasted for a week with nearly uniform atmospheric conditions [4]. The findings
indicate that the output temperature has increased by an average of 400C. The efficiency of both
circumstances was calculated, and a comparison of the results reveals a 21% gain in efficiency
overall.
Wattana et al explain how the PTC's design raises outlet temperature by lowering heat loss.
Since the maximum temperature at the header of the evacuated tube in this design is 235 0c, it is
ideal for high-temperature applications such as industrial purposes. The collector's maximum
efficiency in this design is 32.9% [6].
Dire Dawa and Gode are considered for the eastern part. The maximum measured global solar
radiation has been recorded at both stations during the months of January and February. Similarly,
for both stations, the maximum estimated global solar radiation by all models was observed during
the same month (February). In July, both sites recorded their lowest measured and calculated solar
radiation values. Monthly mean daily global solar radiation values in Dire Dawa range from 4.5
to 7.5 kWh/m2, 4.2 to 7.1 kWh/m2, and 4.4 to 7.4 kWh/m2 for the AP, LO, and GM models,
respectively. In Gode, it ranges from 3.9 to 7.9 kWh/m2, 3.7 to 7.5 kWh/m2, and 3.9 to 7.96
kWh/m2 for the AP, LO, and GM models, respectively. For both stations, the annual mean daily
global solar radiation calculated by all models is greater than 6 kWh/m2 [3].
2.2. Solar Thermal Collectors
A solar thermal collector is a tool used to capture solar heat energy and transmit it to water or other
phase change materials (PCM). As a result, the solar collector can be utilized to heat either the air
or the water. There are primarily two categories of collectors: [8]
48|Page
Flat Plate Collector
It lacks an optical concentrator. Here, the efficiency is low, the working fluid temperature can only
be increased to 700C, and the collection area and absorber area are numerically equal. These are
insulated rectangle boxes with a transparent glass cover, absorber plate, and other features. The
tubes that circulate water through the collector to obtain heat energy through the absorber are
attached to the absorber plate. They are spaced roughly 10 to 15 cm apart.
Figure 18: cross-section of flat plate collector

Flat plate collectors are used for household water heating due to their simplicity and low maintenance
costs.
Evacuated Tube Collectors
An evacuated tube collector is more efficient than a flat plate system and can raise water/steam
temperatures to as much as 350°F (177°C). They often enclose the absorber surface and heat transfer
fluid in a vacuum-sealed tubular glass, making them the most effective type of collector for cold
climates with low-intensity diffuse sunlight.
49|Page
Figure 19: evacuated tube collector

Comparison between flat plate and evacuated tube collectors
▪ It requires less roof area than flat plate collectors
▪ More efficient than flat plate collector due to lower heat losses by convection at lower
ambient air temperatures because of the vacuum air layer in the evacuated tubes.
▪ Evacuated tubes have an efficiency between 550c-670c and flat plates have an efficiency
between 30-400c.
▪ Flat plate collectors are more effective than evacuated tube collectors for low
temperature applications. Yet, evacuated tube collectors are ideal for high-temperature
applications like steam generation.
50|Page
CHAPTER THREE
METHODOLOGY TO DO THE PROJECT
3.1. Overall Methodology
After figuring out the problem with our hosting firm (EABSC Dire Dawa Plant) and choosing the
topic, more discussions were held to clarify the project's idea and goals. The project's background
is then widely researched as part of a literature study using a variety of sources, including journals,
papers, reference books, and data sheets. We have completed the material selection, specification,
and cost analysis following a thorough investigation. To make the system more figurative, develop
a 3D model in AutoCAD, simulate it using proteus software, and write Arduino code. After we
did the above tasks, finally we prepared the final report.
DEFINE THE STUDY MATERIAL

PROBLEM LITERATURE SELECTION AND
REVIEW COST ANALYSIS
DESIGN
DEVELOP DEVELOP 3D IN
SIMULATION IN
PROTEUS ARDUINO CODE AutoCAD software
TEST AND REPORT OR

ANALYSIS DOCUMENTATION
Figure 20: the methodology of our system
3.2. System Components/ Material Descriptions
Here, we'll try to divide our system's components into three parts.
▪ Input section
51|Page
▪ Control section
▪ Output section
INPUT SECTION
Temperature Sensors
The system requires two temperature sensors to detect the temperature of the solar collector and the
temperature of the water entering the storage tank to regulate and control the operation of the hot
water circulation pump. Those are: -
A. Thermocouple
Thermocouples are the most popular type of temperature sensor used in domestic water heating
systems. Two metal wires are simply welded together to create it. The voltage across the wires
would rise with temperature as a result of a physical effect.
Thermocouples are generally inexpensive, as their design and materials are simple. To implement
this project in the real world, we a use Thermocouple sensor.
Figure 21: Thermocouple working principle
Thermocouple working principle
Thermocouples are temperature sensors, which are extensively used for the measurement of
temperature variations. They sense the temperature and the temperature is further measured by other
instruments after sensing it. Since they do not require any external power source to operate, they
are active transducers. The thermocouple working principle is based on the See back Effect. This
effect states that when a closed circuit is formed by joining dissimilar metals at two junctions, and
junctions are maintained at different temperatures then an electromotive force (e.m.f) is induced in
this closed circuit. The amount of induced e.m.f is different for different metal combinations and is
proportional to the temperature difference of the junctions. This is the basic thermocouple working
principle.
52|Page
It has the following specifications:

▪ Operating temperature: -100 to 7000C
▪ Probe material: Stainless steel
▪ Probe diameter: 5mm
▪ Probe length: 100mm
▪ Cable length: 3m
Figure 25
Figure 22: K-type thermocouple probe
B. Thermocouple Amplifier Board
The thermocouples' temperature-voltage relationship is monotonic, not linear. Since the signal
levels from thermocouples are so low, high impedance amplification is required to precisely pick
up and amplify the signal without damaging or distorting its accuracy. To address this issue, one
interface chip is utilized in this project to boost the output signals from the thermocouples.
The thermocouple amplifier board with the MAX31855 Chip can read and digitize thermocouple
output voltages. At 3.3 volts, the MAX31855 is operational.
Specifications of MAX31855:
▪ Measure temperature: -200 ˚C to 1350 ˚C
▪ The input voltage: 3 to 5V DC
▪ Operating current: 900 µA to 1500 µA
▪ Maximum output,voltage: 0.4V
▪ Accuracy: ±2˚C
▪ Outputs: uses SPI data output requires any three digital I/O pins
53|Page
▪ Required sensors: k-type thermocouple
Figure 23: MAX 31855 Breakout Board
C. One Wire Digital Temperature Sensor (DS18B20)
A 1-wire digital temperature sensor is the second temperature sensor that is mounted on the
thermal collector to measure the collector temperature. Information is delivered to and from the
DS18B20 using a one-wire interface since this sensor communicates with the microcontroller
using just one wire.
Figure 24: Dallas (DS18B20) digital temperature sensor interface with Arduino
Features of Dallas (DS18B20):
✓ Doesn’t need external components

✓ Need one port pin for communication
✓ Power supply ranges 3V-5V
✓ Measures -550C to 1250C
54|Page
✓ +/- 0.50C accuracy from -100C to 850C
D. LEVEL SENSOR
Float switches or float sensors are a direct kind of point-level sensor. They act comparably to the float
valve which is a mechanical simple sensor. A mechanical float sensor rises and falls as the level in
the holder changes. When the level arrives at a setup set point, the floating development acts to close
or open a bunch of switch contacts, which represents the moment of truth in an electrical circuit way.
Float sensors are moderately basic gadgets, are reasonable and simple to introduce, yet they should
be submerged in the media being observed to work. Since the float is a mechanical segment that
moves, there is some potential for the float to stick which could deliver the sensor work out of
commission. In our project we use flat level switch for sensing the level of water tank.
Figure 25: float level sensor
E. Power supply
A 220V single-phase AC supply is used to power the centrifugal pump and the best ones to feed the
Arduino and the Solid-State relays used in the project.
F. 12V DC Adapter
A 220V AC to 12V DC converter must be utilized to supply 12V electricity for each relay. Electrical
equipment that needs electricity but lacks internal components to obtain the necessary voltage and
power from mains power is connected to AC adapters. An external power supply's internal circuitry
is remarkably like the architecture of an internal or built-in supply.
55|Page
Figure 26: DC adapter

Specifications:
▪ Input voltage of AC 100-240V
▪ Output voltage 12V 3 Amperes
▪ 5.5 mm power tips
▪ Stabilizing output, low ripple, and low interference
G. Contactor (4 pole, 40 A, 220V)
A contactor is an electrically-controlled switch used for switching and an electrical power circuit
and protecting a motor from high power. It is typically controlled by a circuit with a lower power
level than the switched circuit, such as a 24-volt coil electromagnet controlling a 230-volt motor
switch. Contactors are designed to be directly connected to high-current load devices, and are
usually fitted with normally open ("form A") contacts. Unlike relays, contactors are designed with
features to control and suppress the arc produced when interrupting heavy motor currents.
Figure 27: contactor

H. Single-Phase Circuit Breaker
56|Page
It is used to protect circulating pump and system controls and on/off the power supply. It has two
benefits: the current needed to activate the relay is far less than the switching current that the relay
contacts can handle, and the coil and contacts are galvanically separated, which means that a
microcontroller or other isolated low-voltage digital system can be utilized with the relay to switch
the mains current.
Figure 28: 1-phase circuit breaker

CONTROL SECTION
A. Arduino Uno
Arduino is an open-Source electronic prototyping platform based on flexible easy to use hardware
and software. It consists of a circuit board, which can be programed (referred to as a
microcontroller), and a ready-made software called Arduino IDE (Integrated Development
Environment), which is used to write and upload the computer code to the physical board. We are
going to use it as the microcontroller for our project.
Figure 29: Arduino Uno
57|Page
B. Single-Channel Relay Module
Relay is an electromechanical device that uses an electric current to open or close a switch's contacts.
Its operating voltage is 5 volts and its maximum output is either 250 volts direct current or 30 volts
direct current. A single-channel relay module with an optocoupler and low-level trigger is available
with two benefits: the current needed to activate the relay is far less than the switching current, and
the coil and contacts are galvanically separated, allowing a microcontroller or other isolated low-
voltage digital system to be used to switch the mains current.
Figure 30: single-channel relay

Specifications of Single-Channel Relay Module:
▪ Supply voltage – 3.75V to 6V
▪ Current when the relay is active: ~70mA
▪ Relay maximum contact voltage – 250VAC or 30VDC
▪ Relay maximum current – 10A
OUTPUT SECTION
A. 16×4 Liquid Crystal Display (LCD)
It is one kind of electronic display module used in an extensive range of applications like various
circuits & devices like mobile phones, calculators, computers, TV sets, etc. These displays are
mainly preferred for multi-segment light-emitting diodes and seven segments. The main benefits of
using this module are inexpensive; simply programmable, has animations, and there are no
limitations for displaying custom characters, special and even animations, etc. The operating voltage
of 16×4 LCD is 4.7V-5.3V. It includes four rows and each row can produce 16 characters. The
utilization of current is 1mA with no backlight.
58|Page
Figure 31: 16x4 LCD Display
B. Circulating Pump
A solar heat pump system consists of solar collectors, heat pump units, a heat storage water tank,
and associated hardware. A hot water circulation pump is used to circulate fluid to the collector, and
the temperature of the cooling system can be raised by 20-300c during the cycle. Energy from the
storage tank is taken and transmitted to the heat pump unit's evaporator, and the fluid is moved
through the solar thermal collector by a pump.
A pump's main function is to provide the appropriate pressure head to manage flow rate and energy
collection, raising the heat pump's evaporator temperature and lowering the operating temperature
of the collector. High pumping is measured in m (H), maximum volume flow rate
(Q), and pump efficiency (ɳ). A revolving impeller is used by a centrifugal pump to boost the
fluid's pressure and flow rate due to centrifugal force.
Advantages of centrifugal pump:
▪ Flat flow
▪ Uniform discharge pipe pressure
▪ Low cost
▪ Quick operation
59|Page
Figure 32: a cross-sectional view of the centrifugal pump

The pump power of the system is calculated as:
Where: P = power of pump (KW)

= density of water (kg/m3)
g = gravity (9.81 m/s2)
Q = flow capacity (m3/h)
h = differential head (m)
The project's estimated assumed flow rates for the heat transfer fluid are (0.5 ), (10 m) for the
differential head, and (1000Kg/m3) for water, respectively.
The shaft power of pump can be calculated us:
Other supplementary materials used

A. Designing of the Solar Collector
In a solar system that uses a collector to raise the temperature of the heat transfer fluid, which is
then utilized to transport heat to the heat exchanger and transform solar energy into heat energy,
60|Page
the solar collector is regarded as the system's central component. The tank's water is then heated
using the converted energy. A solar collector known as an evacuated tube collector, which is
constructed of double-layer borosilicate glass tubes and serves as insulation in the system, is used
in our system. Moreover, it distributes heat to the water that is flowing through the inner tube and
aids in the absorption of solar energy. Most of the copper is used to make water tubes in solar
collectors. Both direct solar radiation and heat transferred through the solar collector are absorbed
by these pipes. Thermal conduction losses are prevented by evacuation, but radiation losses cannot
be decreased by achieving a vacuum.
Figure 33: evacuated tube solar collector

Calculation of Annual Energy Demand
The equation for calculating annual energy demand is: -
QT = Qw + Qloss where Qloss is the loss of the system
Qloss = QSTL + QCIR
Our system design to heat 4-5m3 of water per day, Ti = 500c = 323k and Tf =800c= 353k
CP=4.186J/g0c=1.16KWh/m3k, where CP –water heat capacity
QW=m CPT QW useful energy needed to heat water
T - temperature difference between hot water and cold water in
the inlet and outlet of the tank
m-storage capacity of the tank (volume of water); m=5m3
QW=m CPT=5m3*1.16KWh/m3k*(353k-323k) = 174KWh/day
Assume the storage tank and pipes are well insulated to minimize the loss in the system.
61|Page
Storage tank loss is QSTL=2.6KWh/day and loss in the circulation let’s assume QCIR=5%*Qw,
QCIR=5% *174KWh/day=8.7KWh/day where, QSHL- storage tank loss, QCIR is circulation loss in
the pipes.
Daily energy demand can be calculated as:
QT= QW+ QSTL+ QCIR
QT = (174 +2.6 + 8.7) KWh/day=185.3KWh/day
Our system runs (works) six days a week, with one of those days the boiler is getting preventive
maintenance. Out of 365 days in a year, 313 days the system is operational or in use.
Annual Energy Demand is calculated by using the equation:
Qannual= QT*313KWh/year=57,998.9 KWh/year
Sizing of a solar collector
Global solar radiation in the Dire Dawa location [3].
Location Dire Dawa
Latitude 9.970N
Longitude 42.53E
Altitude 1180m
Table 2: solar radiation in the Dire Dawa

The solar collector area was calculated by using the following procedure:
Annual solar radiation between 4.5-7.5 KWh/m2
Jan Feb march April May June July Aug Sep Oct Nov dec
7.3 7.5 7.1 6.2 5.3 4.6 4.5 5 5.8 6.5 7.0 7.1
Table 3: annual solar radiation in Dire Dawa
The annual average value of solar energy for Dire Dawa is about 6.2 KWh/m2/day, this is global
horizontal irradiance, and this location receives the maximum solar irradiance in January and
February.
Sizing calculation for the annual energy demand of a solar collector
The following methods can be used to compute the area of a solar collector:
62|Page
Qsolar= Qannual* Sf where Sf -the value of solar fraction=100%=1

Qsolar=57,998. 9KWh/year
Annual radiation of solar energy in Dire Dawa is about Iav=6.2 KWh/m2 per day
Annual radiation Iav=6.2 KWh/m2/day*313 day=1940.66.2 KWh/ m2 per year Area
of collector, AC= Qsolar/ Iav
Ac
AC=29.887m2
The formula above can be used to determine the collector, however, it is predicated on certain data
assumptions, such as the temperature of the intake and output collection.
B. Designing of Storage tank
A 6 m3 insulated water tank is used to efficiently store thermal energy. Storage tanks made of
stainless steel and copper have great properties including durability, longevity, and resistance to
corrosion. The thermal storage tank is made of high-pressure-resistant stainless steel that has been
wrapped with insulated fiber and aluminum foil. Using water pumps, our solar water heaters move
heated water from storage tanks via exposed pipes and collectors. When there is no sunlight, the
boiler machine consumes the stored energy. To calculate the permissible storage tank capacity
volume, estimation of monthly and annual values in accordance with volume changes is required.
63|Page
Figure 34:storage tank (hot well tank)

C. Heat Exchanger
Heat exchangers are used to transferring thermal energy between two or more fluids, such as cold
and hot water. They come in a variety of forms, such as closed systems, parallel flow, counter flow,
multi-pass, and cross-flow. When designing, assumptions can be made about constant properties,
minimal heat loss to the environment, minimal tube wall thermal resistance, and minimal fouling
issues. The energy balance for a hot fluid may reveal the necessary heat transfer rate.
A heat exchanger is typically used according to flow. The average temperature of the water inlet to
the heat exchanger is between 65 and 900c, and the outlet temperature is between 20 and 350c, while
the flow rate varies in temperature and the amount of heat which it gets from the solar collector. In
our project, we assumed the effectiveness of the heat exchanger in the range 0.6 to 0.8 by increasing
size of exchanger.
64|Page
Figure 35: heat exchanger

D. Connection (hookup wires)
Connecting wires allows an electrical current to travel from one point on a circuit to another because
electricity needs a medium through which to move. We used those wires to connect the whole
components.
E. Breadboard (circuit board)
Construction and testing of prototypes are done on a breadboard. For electronic experiments, it is
crucial. It is a piece of plastic that is used to support electronic components when creating
electronic circuit prototypes.
Figure 36: Breadboard
65|Page
F. Heat Transfer Fluid
Heat transfer fluids must have a high specific heat capacity, a high thermal conductivity, a low
viscosity, and a low thermal expansion coefficient anticorrosive characteristic to be used in an
efficient solar water heater design.
Water is the most cost-effective and thermally efficient material for the project, as there is little chance
of freezing in Dire Dawa.
G. Piping
The most significant information in this article is that copper pipe is utilized in most systems
because of its longevity, resistance to corrosion, and ability to withstand extremely high
temperatures. Tubing is used to provide a conduit for the conveyance of fluid. The only materials
that should be utilized in direct solar systems that use potable water are copper, brass, and bronze.
Depending on its use, local laws, and customs, the pipe should either be replaced or isolated using
dielectric unions. The tube is additionally employed as support while constructing protracted
system piping lines.
66|Page
CHAPTER FOUR
SYSTEM DESIGN AND ANALYSIS
4.1. Operation flow chart of the system
In this project, Arduino Uno act as our primary controller along with other sensors to control the
whole system. We employed a two-temperature sensor to detect the temperature of the collector
and storage tank, and, we used the level sensor to detect the level of water in the storage tank.
These sensors provide information to the controller (Arduino Uno). The relay receives output from
the controller, which serves as a CPU. Based on the output command, the circulating pump, and
inlet water pump can be controlled in the following manner:
Level Sensors Operation
We employ a float potentiometer level sensor to detect the level of water in the tank. It can operate
in the following way in our system.
▪ When the storage tank's level and temperature are first sensed, as well as the solar
collector's temperature, by the level and temperature sensors. The intake water pump and
the circulatory pump both use them as input.
▪ The level sensor senses the storage tank level and changes the position by sliding up and
down to the water and processing the signal to send the controller.
▪ The Arduino based on the loaded program, commands the Solid-State Relay either to
turn ON or turn OFF the inlet water pump.
▪ If the level sensor detects the presence of water below 25%, the water pump is ON.
▪ If the sensor detects the presence of the water above 75%, then the water pump is turned
OFF.
▪ If the level detects the level between 25% and 75%, then the water pump continues to
the previous operation.
Temperature Sensors Operation
Our system uses two temperature sensors to measure the temperature in the solar collector and tank,
and level sensors in the tank, which are used to drive the circulating pump.
▪ The temperature sensor (thermocouple) starts to measure the temperature in the
tank, and one wire (DS18B20) temperature sensor starts to measure the temperature
in the solar collector.
67|Page
▪ If the temperature of water in the tank is greater than or equal to 800c, and the level
of water is below 25%, then the circulating pump is OFF.
▪ If the temperature of water in the tank is below 800c, the temperature of the solar
collector is greater than the temperature of water in the tank by 20c, and the level is
above 25%, then the Arduino commands the circulating pump ON.
▪ If the temperature of water in the tank is below 800c, and the temperature of the
solar collector is less than or equal to the temperature of the storage tank, then the
circulating pump is OFF. This operation can be used to ignore the circulation in
night and rainy day to prevent loss of heat from the tank.
▪ Parallel to the above operations of monitoring and controlling of the filling, and
circulation the LCD displays the two pump states, temperature of the tank, and level
of the storage tank.
Solar PUMP
collector
Thermocouple Hot
e Water
PUMP
Level tank
sensor
Arduino RELAY
Uno
(controller
DS18B20 ) RELAY
Temperature
sensor LCD
Figure 37: general block diagram of the system
68|Page
Figure 38: General operation flowchart of the system

4.2. SYSTEM DESIGN
4.2.1. AutoCAD 3D Design
Figure 39:3D AutoCAD Design
69|Page
4.2.2. Schematic Design of proteus simulation
Figure 40:Schematic diagram of the system

Circuit Explanation:
The circuit of this automatic solar water heater Project is very simple it contains Arduino Uno for
controlling whole the process of the project, a level sensor detects the water level, temperature
sensor to sense the temperature of the solar collector and water in the tank , a circulating pump to
pump the phase change material (heat exchanging fluid) from the tank to the solar collector, water
pump for inlet water in the tank, and 16x4 LCD for displaying the state of pumps, level, and
temperature of the storage tank.
The level sensor connects directly Trig Pin to A0 and Echo Pin to A1, one wire (DS18B20)
temperature sensor connects to pin D5, the LM35 connects to analog pin A3, circulating pump
connect to D4, water pump connects to pin D3, and a 16x4 LCD is configured in 4-bit mode and
its RS, EN, D4, D5, D6, and D7 are directly connected at Digital pin D8, D9, D10, D11, D12,
and D13 of Arduino.
70|Page
4.3 Cost Analysis
Economic Performance and Installed Cost Analysis

According to the boiler HFO consumption record in EABSC Dire Dawa Plant records, the minimum
consumption of HFO (heavy fuel oil) is 320 liters/day, and the maximum consumption is 1430
liters/day.
The average consumption of HFO is 320+1430=1750/2=875 liters/day, now let’s change to energy
1litter HFO is a capacity to produce 10.38KWh of energy, and the boiler consumes 9082.5KWh/day.
HFO cost=48 birr/liter; 1litter HFO=10.38 KWh
48 birrs=0.89$ in dollars, this cost is the current cost of HFO
0.89$/litter=0.89$/10.38 KWh => 0.086$/KWh, its’ costs to produce 1KWh of energy.
Cost of HFO per day
1litter=0.89$, cost of HFO per day is 778.75 $
Annual energy cost
Xannual = (778.75$*313) = 243,748.75$/year
Annual energy consumption of the boiler
Xannual energy=9082.5Kwh/day*313=2,842,822.5 KWh/year. This is boiler consumes per year to
produce steam in the boiler.
Energy saving by our system
Our system generates, Qsolar=185.3 Kwh/day to heat up the water before entering to the boiler.
1litter = 10.38 Kwh
Qsaving=17.85 liter/day, our system replaces 17.85 liters of HFO by renewable energy per day
Annual HFO Saving
Qsaving =17.85liter/day*313 = 5477.5 liter/year

Our system replaces 5477.5 liter of HFO consumption by solar thermal energy.
Annual Cost Saving
The cost of HFO fluctuates between 40-70 birr throughout the year.
Cost_avg = (40+70)/2=55 birr/liter, 55birr=1.02$/liter
1liter=1.02 $
5477.5liter=?
71|Page
Cost saving per year= 5587.05$/year

This project saves 5587.05$/year of HFO cost.
INVESTMENT INITIAL COST

The initial investment cost to install our system is calculated in the below, after calculating the
investment cost, we can find the payback period of our system.
Solar collector cost
C=Csolar *Ac where, C-cost of installed solar system in dollar
Ac=area of collector
Cs=cost of solar collector($/m2)
Cost of solar collector in the market is depending on the system size and application. In our system,
we select evacuated tube collector to get higher heat with minimal loss in the system, and to get
higher heat in small roof area.
For large system 400$/ m2
For a small system 1000$/ m2
Average = (400+1000)/2=700$/ m2
C=700$/m2*29.887 m2
C=20,920.9 $ it’s solar collector costs.
Description Type Value Quantity Cost(dollar)

Arduino Uno 5V/16MHZ 1 48
SSR Relay 5V 3 17
Centrifugal 0.25-4.4KW 1 100
Pump 2900rpm
110-660V
LCD 16X4 1 9
Breadboard White 1 7
copper
Float 1 19
potentiometer
level sensor
72|Page
Digital DS18B20 1 7
temperature
sensor
Thermocouple 1 13
12 V DC 1 20
adapter
Contactor 4Pole 40A/220V 1 11
Circuit Single 1 4
breaker phase
Solar Evacuated 1 20,920.9
collector tube
Total 21230.9 $
Table 4: total investment cost
Payback Period
Payback=
Payback=
Pay back= 3.8 year, which means around four years to pay the investment cost.
73|Page
CHAPTER FIVE
RESULT AND DISCUSSION
5.1. Simulation Result
After writing the code in the Arduino integrated development environment (IDE) editor, the code
will be compiled to produce a hex file, which denotes that the file is in hexadecimal format. Finally,
after creating the circuit in the proteus program, as shown before, we finally upload the hex file to
the Arduino and run the simulation to obtain the results shown in the figure below. The code is
visible in the appendix.
Figure 41: First step after simulation

If the level is less than or equal to 25%, and the water tank temperature (Tt) is greater than or equal
to 80 0C, then the WATER PUMP is ON, and CIRCULATING PUMP is OFF.
74|Page
Figure 42: simulation result 1

If the level is less than or equal to 25%, and the water tank temperature less than 800c, and the
temperature difference between solar collector (Tc) and the water tank (Tt) is greater than 2 0c,
then the WATER PUMP is ON, and CIRCULATION PUMP is OFF.
75|Page

If the level is between 25% and 75%, and tank temperature is greater than or equal to 800c, and the
tank level transition state from low to high (L-H) increases, then the WATER PUMP is ON and
CIRCULATING PUMP is OFF.

If the level is between 25% and 75%, and tank temperature is less than 800c, temperature difference
between solar collector (Tc) and the water tank (Tt) is greater than 20c, and the tank level transition
state from low to high (L-H) increases, then the WATER PUMP is ON and CIRCULATING
PUMP is ON.
76|Page
Figure 45:simulation result 4

If the level is greater than or equal to 75%, and tank temperature is less than 80 0c, temperature
difference between solar collector (Tc) and the water tank (Tt) is greater than 20c, then the WATER
PUMP is OFF and CIRCULATING PUMP is ON.
77|Page
If the level is greater than or equal to 75%, and tank temperature is greater than 800c, then the
WATER PUMP is OFF and CIRCULATING PUMP is OFF.

If the level is between 25% and 75%, and tank temperature is less than 800c, temperature
difference between solar collector (Tc) and the water tank (Tt) is greater than 20c, and the tank
level transition condition from high to low (H-L) decreases, then the WATER PUMP is OFF and
CIRCULATING PUMP is ON.
78|Page
If the level is greater than or equal to 75%, and tank temperature is less than 800c, temperature
difference between solar collector (Tc) and the water tank (Tt) is less than or equal to 20c, then the
WATER PUMP is OFF and CIRCULATING PUMP is OFF.
5.2. Discussions
5.2.1. Controlling System Discussion
The automatic water heating system using solar thermal energy is an autonomous closed-loop
Arduino-based system that is intended to automatically control the fluid flow and level of the water
tank in the solar water heater by using temperature and level sensors to perform (accomplish) both
the general and specific goals of the project. Once loaded onto the Arduino Uno board, this project
executes in accordance with the Arduino software.
Based on the main outputs of the project, the following results are obtained:
In our idea, the tank's inlet water is pumped using a water pump. It can only be controlled by level
sensor input. Heat exchanger fluids (water) are pumped from the water tank into the solar collector
using a circulating pump. Both the temperature of the water tank and the temperature of the solar
collector, as well as the level sensor, are inputs used by Arduino to regulate it.
79|Page
▪ WATER PUMP ON: Considering the initial level of the storage tank, if the level is less
than 25%, the Arduino sends a digital HIGH signal to the SSR relay to turn ON the water
pump.
▪ WATER PUMP HOLD: when the level of the tank is between 25% & 75%, it follows
their states (if the tank is start to pump to the tank it continues in ON state until reaches 75%
(L-H), and after reach 75% the pump is OFF, then the pump continues in OFF state until
reaches 25%(H-L).
▪ WATER PUMP OFF: when the level sensor reads the level of the tank is greater than or
equals to 75%, then the Arduino commands the SSR relay to turn OFF the water pump.
▪ CIRCULATING PUMP ON: when the level of water tank is greater than 25%, water tank
temperature is less than 80%, and the temperature difference between solar collector and
water tank is greater than 20c, the circulating pump is in ON state.
▪ CIRCULATING PUMP OFF: this pump is OFF state in three cases:
o When the level of water tank is less than 25%.
o When the water tank temperature is greater than 800c

o When the temperature difference between solar collector and water tank is
less than or equal to 20c. This condition is used to prevent our pump work in the
night, and heat loss from storage tank.
Due to the system's autonomy, these outcomes occur throughout the plant's operational state unless
the power is manually turned off at the power circuit breaker.
5.2.2 Cost Analysis Discussion
Our key goal is to build a system that is economical in order to complete our project successfully.
To do this assignment, we research market material costs to determine the investment cost. We
estimated the initial cost and then the payback times. Our system covered their initial investment
cost in about 4 years, and this installation is guaranteed to last for at least 20 years and up to 40
years.
80|Page
CHAPTER SIX
CONCLUSION AND RECOMMENDATION
6.1 Conclusion
Our project's main goal is to produce a cost-effective automatic water heater that uses solar thermal
energy to provide hot water to the boiler machine. EABSC Dire Dawa Plant needs to build a system
that is cost-effective by lowering the boiler's consumption of HFO (heavy fuel oil). Our technology
minimizes HFO consumption by developing a solar water preheater, which uses renewable energy,
and pays for itself in four (4) years or less. Since our system lasts at least 20 years, this shows that
our project is cost - effective. Hence, we have achieved our primary objectives of the project. The
second objective involves developing a 3D model in AutoCAD software, simulating it in proteus,
manipulating it there, and designing a control mechanism using Arduino Uno with the aid of key
parts like temperature sensors and level sensors, which act as inputs and Arduino controls the state
of the pump. Temperature, level, and pump status are all displayed on the LCD. Successful design
of the 3D model and proteus simulation configuration. As a result, it achieved our second set of
intended goals.
In general, our systems achieved our objectives by improving boiler productivity and efficiency,
decreasing the occurrence of thermal shock in the boiler, increasing the life span of the boiler, and
decreasing the emission of greenhouse gas into the atmosphere.
6.2 Recommendation
We would like to suggest to the engineering division as well as the corporate managers that this
work be implemented in order to reduce HFO use, boost boiler machine productivity, efficiency,
and lifespan, and create an automatic control system. The difficulty is that there is a large daily
consumption of HFO, as was previously discussed. The system implemented in our project will last
at least 20 years, and the costs will be recovered within four years. The company so utilizes the
roughly 16-year period without paying charges. Our project is cost effective and reliable in Dire
Dawa, so the company should use our project to reduce the HFO consumption and reduce cost, to
improve the performance and productivity of boiler, and increase life span of the machine.
81|Page
Reference
[1] A Date, C Dixon and A Akbarzadeh,. “Theoretical and Experimental Study on Heat Pipe
Cooled Thermoelectric Generators with Water Heating using Concentrated Solar Thermal
Energy, Solar Energy.” (2014): 105, 656–668.
[2] Kalogirou, Soteris A. “solar thermal collectors and applications.” (2004): 231-295.
[3] Natei Ermias Benti, Abreham Berta Aneseyee, Ashenafi Abebe Asfaw. “Estimation of
global solar radation using sunshine based models in ethiopia.” (2022): 11-14.
[4] P.Rhushi parasad , H.V. Byregowda, P.B Gangavati . “experiment analayisis of flat plate
collector and comparison of performance with tracking collector.” Eroupean Journal of
scientific Research (n.d.): 1450-216.
[5] Samara Sardin, Ehsanul Mohith, Maherin Hossain. “Alternative solar water heater for
domestic purpose.” (n.d.).
[6] smith, Wattana Rati. “The 25th international conference A Novel Non-Tracking Solar
collector for high-temperature application.” the 25th international conference on efficiency,
cost, optimization, simulation, and environmental impact of energy systems (2012).
[7] EABSC DD plant machine data and principal manuals.
[8] Chiaro, B.D. (2007). Solar water heating. Environment California Research & Policy Center.
20PP.
[9] Department of Climate Change and Energy Efficiency. (2010). Solar & heat pump hot water
systems. A Joint Initiative of the Australian State and Territory Governments
[10] Hooman, K. (2015). Analysis and Optimization Design of a Solar Water Heating System
Based on Life Cycle Cost Using a Genetic Algorithm. Urban development institute, Korea.
[11] International Journal of Thermal Engineering (IJTE)Volume 6, Issue 1, June 2018, pp. 18 ,
Article ID: IJTE 6_01_003
82|Page
Appendix
#include<LiquidCrystal.h> lcd.print("Tc=");
#include <NewPing.h> lcd.print(collector_T);
LiquidCrystal lcd(8,9,10,11,12,13); lcd.write(0b11011111);
#define DS18B20_PIN 5 lcd.print("C");
#define C_PUMP 4 lcd.setCursor(0,1);
#define W_PUMP 3 lcd.print("TANK IS 75%");
#define trig A0 digitalWrite(C_PUMP,LOW);
#define echo A1 digitalWrite(W_PUMP,LOW);
#define analogpin A2 lcd.setCursor(0,2);
int C_temp; lcd.print("C_PUMP OFF");
int collector_T; lcd.setCursor(0,3);
int temp = 1; lcd.print("W_PUMP OFF");
int tempDif=0; temp=1;
long duration, distance; }
void setup() { else if((distance > 250 && distance < 750)
lcd.begin(16,4); && tank_T >= 80 && temp==1)
pinMode(analogpin, INPUT); {
pinMode(trig,OUTPUT); lcd.setCursor(0,0);
pinMode(echo,INPUT); lcd.print("Tt=");
pinMode(C_PUMP, OUTPUT); lcd.print(tank_T);
pinMode(W_PUMP, OUTPUT); lcd.write(0b11011111);
lcd.print("WELCOME TO"); lcd.print("C");
lcd.setCursor(0,1); lcd.setCursor(9,0);
lcd.print("OUR INTERNSHIP"); lcd.print("Tc=");
lcd.setCursor(2,2); lcd.print(collector_T);
lcd.print("PROJECT"); lcd.write(0b11011111);
delay(1000); lcd.print("C");
lcd.clear(); lcd.setCursor(0,1);
} lcd.print("LEVEL HOLD L-H");//LEVEL
void loop() { TRANSITION STATE FRO LOW TO HIGH
lcd.clear(); digitalWrite(C_PUMP,LOW);
digitalWrite(trig,LOW); digitalWrite(W_PUMP,HIGH);
delayMicroseconds(2); lcd.setCursor(0,2);
digitalWrite(trig,HIGH); lcd.print("C_PUMP OFF");
delayMicroseconds(10); lcd.setCursor(0,3);
digitalWrite(trig,LOW); lcd.print("W_PUMP ON");
duration = pulseIn(echo,HIGH); }
distance = duration*0.017; else if((tank_T<80 && tempDif> 2) &&
distance = constrain(distance,0,1000); (distance > 250 && distance < 750) &&
int tank_T= analogRead(analogpin); temp==1)
tank_T = tank_T*0.48828125; {
ds18b20_read(&C_temp); lcd.setCursor(0,0);
collector_T = C_temp / 16; lcd.print("Tt=");
83|Page
tempDif = collector_T - tank_T; lcd.print(tank_T);

if(tank_T>=80 && distance >= 750) lcd.write(0b11011111);
{ lcd.print("C");
lcd.print("Tt="); lcd.print("Tc=");
lcd.print(tank_T); lcd.print(collector_T);
lcd.write(0b11011111); lcd.write(0b11011111);
lcd.print("C"); lcd.print("C");
lcd.print("Tc="); lcd.print("LEVEL HOLD L-H");
lcd.print(collector_T); digitalWrite(C_PUMP,HIGH);
lcd.write(0b11011111); digitalWrite(W_PUMP,HIGH);
lcd.print("C"); lcd.setCursor(0,2);
lcd.setCursor(0,1); lcd.print("C_PUMP ON");
lcd.print("TANK IS 25%"); lcd.setCursor(0,3);
digitalWrite(C_PUMP, LOW); lcd.print("W_PUMP ON");
digitalWrite(W_PUMP, HIGH); }
lcd.setCursor(0,2); else if((tank_T<80 && tempDif <= 2)
lcd.print("C_PUMP OFF"); && (distance > 250 && distance < 750) &&
lcd.setCursor(0,3); temp==1)
lcd.print("W_PUMP ON"); {
temp=0; lcd.setCursor(0,0);
} lcd.print("Tt=");
else if ((tank_T < 80 && tempDif > 2) && lcd.print(tank_T);
(distance >= 750)) lcd.write(0b11011111);
{ lcd.print("C");
lcd.print("Tt="); lcd.print("Tc=");
lcd.print(tank_T); lcd.print(collector_T);
lcd.write(0b11011111); lcd.write(0b11011111);
lcd.print("C"); lcd.print("C");
lcd.print("Tc="); lcd.print("LEVEL HOLD L-H");
lcd.print(collector_T); digitalWrite(C_PUMP,LOW);
lcd.write(0b11011111); digitalWrite(W_PUMP,HIGH);
lcd.setCursor(0,1); lcd.print("C_PUMP OFF");
lcd.print("TANK IS 25%"); lcd.setCursor(0,3);
digitalWrite(C_PUMP, LOW); lcd.print("W_PUMP ON");
lcd.setCursor(0,2); else if((tank_T<80 && tempDif > 2) &&
lcd.print("C_PUMP OFF"); distance < 250)
lcd.setCursor(0,3); {
lcd.print("W_PUMP ON"); lcd.setCursor(0,0);
temp=0; lcd.print("Tt=");
84|Page
} lcd.print(tank_T);
else if ((tank_T < 80 && tempDif <= 2) lcd.write(0b11011111);
&& (distance >= 750)) lcd.print("C");
{ lcd.setCursor(9,0);
lcd.setCursor(0,0); lcd.print("Tc=");
lcd.print("Tt="); lcd.print(collector_T);
lcd.print(tank_T); lcd.write(0b11011111);
lcd.write(0b11011111); lcd.print("C");
lcd.setCursor(9,0); lcd.print("TANK IS 75%");
lcd.print("Tc="); digitalWrite(C_PUMP,HIGH);
lcd.print(collector_T); digitalWrite(W_PUMP,LOW);
lcd.write(0b11011111); lcd.setCursor(0,2);
lcd.print("C"); lcd.print("C_PUMP ON");
lcd.print("TANK IS 25%"); lcd.print("W_PUMP OFF");
digitalWrite(C_PUMP, LOW); temp=0;
lcd.setCursor(0,2); else if((tank_T<80 && tempDif <= 2)
lcd.print("C_PUMP OFF"); && distance < 250)
lcd.setCursor(0,3); {
lcd.print("W_PUMP ON"); lcd.setCursor(0,0);
temp=0; lcd.print("Tt=");
} lcd.print(tank_T);
else if(tank_T>=80 && (distance > 250 lcd.write(0b11011111);
&& distance < 750) && temp==0) lcd.print("C");
{ lcd.setCursor(9,0);
lcd.setCursor(0,0); lcd.print("Tc=");
lcd.print("Tt="); lcd.print(collector_T);
lcd.print(tank_T); lcd.write(0b11011111);
lcd.write(0b11011111); lcd.print("C");
lcd.setCursor(9,0); lcd.print("TANK IS 75%");
lcd.print("Tc="); digitalWrite(C_PUMP,LOW);
lcd.print(collector_T); digitalWrite(W_PUMP,LOW);
lcd.write(0b11011111); lcd.setCursor(0,2);
lcd.print("C"); lcd.print("C_PUMP OFF");
lcd.print("HOLD STATE H-L" ); lcd.print("W_PUMP OFF");
digitalWrite(C_PUMP,LOW); temp=0;
digitalWrite(W_PUMP,LOW); }
lcd.setCursor(0,2); delay(500);
lcd.print("C_PUMP OFF"); }
lcd.setCursor(0,3); bool ds18b20_start(){
lcd.print("W_PUMP OFF"); bool ret = 0;
85|Page
} digitalWrite(DS18B20_PIN, LOW);
else if( (tank_T < 80 && tempDif > 2) && pinMode(DS18B20_PIN, OUTPUT);
(distance > 250 && distance < 750) && delayMicroseconds(500);
temp==0) pinMode(DS18B20_PIN, INPUT);
{ delayMicroseconds(100);
lcd.setCursor(0,0); if (!digitalRead(DS18B20_PIN)) {
lcd.print("Tt="); ret = 1;
lcd.print(tank_T); delayMicroseconds(400);
lcd.write(0b11011111); }
lcd.print("C"); return(ret);
lcd.setCursor(9,0); }
lcd.print("Tc="); void ds18b20_write_bit(bool value){
lcd.print(collector_T); digitalWrite(DS18B20_PIN, LOW);
lcd.write(0b11011111); pinMode(DS18B20_PIN, OUTPUT);
lcd.print("C"); delayMicroseconds(2);
lcd.setCursor(0,1); digitalWrite(DS18B20_PIN, value);
lcd.print("LEVEL HOLD H-L"); delayMicroseconds(80);
digitalWrite(C_PUMP,HIGH); pinMode(DS18B20_PIN, INPUT);
digitalWrite(W_PUMP,LOW); delayMicroseconds(2);
lcd.setCursor(0,2); }
lcd.print("C_PUMP ON"); void ds18b20_write_byte(byte value){
lcd.setCursor(0,3); byte i;
lcd.print("W_PUMP OFF"); for(i = 0; i < 8; i++)
} ds18b20_write_bit(bitRead(value, i));
else if( (tank_T < 80 && tempDif <= 2) }
&& (distance > 250 && distance < 750) && bool ds18b20_read_bit(void) {
temp==0) bool value;
{ digitalWrite(DS18B20_PIN, LOW);
lcd.setCursor(0,0); pinMode(DS18B20_PIN, OUTPUT);
lcd.print("Tt="); delayMicroseconds(2);
lcd.print(tank_T); pinMode(DS18B20_PIN, INPUT);
lcd.write(0b11011111); delayMicroseconds(5);
lcd.print("C"); value = digitalRead(DS18B20_PIN);
lcd.setCursor(9,0); delayMicroseconds(100);
lcd.print("Tc="); return value;
lcd.print(collector_T); }
lcd.write(0b11011111); byte ds18b20_read_byte(void) {
lcd.print("C"); byte i, value;
lcd.setCursor(0,1); for(i = 0; i <8; i++)
lcd.print("LEVEL HOLD H-L"); bitWrite(value, i, ds18b20_read_bit());
digitalWrite(C_PUMP,LOW); return value;
digitalWrite(W_PUMP,LOW); }
lcd.setCursor(0,2); bool ds18b20_read(int *raw_temp_value)
lcd.print("C_PUMP OFF"); {
lcd.setCursor(0,3); if (!ds18b20_start())
86|Page
lcd.print("W_PUMP OFF"); return(0);

} ds18b20_write_byte(0xCC);
else if(distance <= 250 && tank_T >= 80) ds18b20_write_byte(0x44);
{ while(ds18b20_read_byte() == 0);
lcd.setCursor(0,0); if (!ds18b20_start())
lcd.print("Tt="); return(0);
lcd.print(tank_T); ds18b20_write_byte(0xCC);
lcd.write(0b11011111); ds18b20_write_byte(0xBE);
lcd.print("C"); *raw_temp_value = ds18b20_read_byte();
lcd.setCursor(9,0); *raw_temp_value |= (unsigned
int)(ds18b20_read_byte() << 8);
return(1);
}
87|Page

Untitled

Uploaded by

Copyright:

Available Formats

Untitled

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Untitled

Uploaded by

Copyright:

Available Formats

DIRE DAWA UNIVERSITY INSTITUTE OF TECHNOLOGY

SCHOOL OF ELECTRICAL AND COMPUTER ENGINEERING

FINAL REPORT AND PROJECT

Advisor Name: Mr. Nurye H. & Mr. Alemayehu T.

SUBMISSION DATE: - 27/06/2015 E.C

Dire Dawa, Ethiopia

Name of Student Date Signature

1. Seid Juhar ------------- -------------

Name of Academic Advisor Date Signature

--------------------------------- ---------------------- ---------------

Name of Company supervisor Date Signature

------------------------- ---------------------- -------------

2.3.6. Bottle washer machine ............................................................................................................ 31

LITERATURE REVIEW ......................................................................................................................... 47

Figure 30: 16x4 LCD Display ...................................................................................................... 59

Table 1: quality parameter and standard of water treatment plant ............................................................ 20

PART ONE: INTERNSHIP REPORT

BACKGROUND OF THE COMPANY

1.2. History of The Company

1.3. Vision, Mission and Values of The Company

1.3.1. Vision of The Company

1.3.2. Mission of The Company

1.3.3. Values of The Company

1.4. Main Services of The Company

1.5. The Main Customers of The Company

1.6. The Overall Organization and Work Flow

Manufacturing Engineering Quality Logistics

Figure 1: overall organizational structure

1.6.2. Workflow of the company

Empty glass Full glass ware

Outlet Consumer Outlet

Figure 2: work flow of the company

OVERALL INTERNSHIP EXPERIENCE

2.1. How We Get into The Company

Production and Packaging Section

2.3. Working Flow in Each Section of The Company

2.3.1. Water Treatment

Figure 3: water treatment plant

Process description of water treatment

e) Activated carbon filter

Microfiltration is type of physical filtration process where contaminated fluid is passed

g) Reverse osmosis (RO)

Figure 4: overall process of water treatment plant

Equipment in water treatment plant

▪ PH Meter and flow meter

Quality parameter and standards of water treatment plant

Check point Parameter Standards

let Chlorine 1-3 ppm

Carbon filter PH 6.5-8.5

Table 1: quality parameter and standard of water treatment plant

2.3.2. Waste Water Treatment Plant

Source of the waste water and its behavior

Waste Water Treatment Plant component and its descriptions

Figure 5: grit channel

Figure 6: Oil Trapping Channel

Figure 8: flow chart of waste water treatment plant

Waste Water treatment plant Laboratory tests

2.3.3. Boiler Room

Figure 9: fire tube boiler

Water Smoke Bottle washer