Addis Ababa Institute of Technology

Department of Electrical & Computer Engineering

Final Internship Report

Name:- Daniel Gebreyohannes

ID:- ATR/3676/05
Hosting Company:- Metal and Engineering
Corporation(METEC, Locomotive Branch)

Internship Period:- March 08 July 08 2016

Submission date:- October 13, 2016

Awraris Getachew

Mengesha

I would like to thank Addis Ababa Institute of Technology and mainly the
Electrical and Computer Engineering School for arranging this four-month
internship period. Next, I would like to thank Nebyu Dereje for coordinating the
internship. Our supervisors whom they helped us in any way they can without
selfless and great devotion.
Among these individuals I want to express my deepest thank to my mentor Awraris
Getachew who help me every time I seek his advice. Then I would like to thank
my company supervisor, Electrical Engineer Samuel Mengesha for his valuable
genuine suggestion& his continuous follow up.
I have also a great thank, appreciation & respect for workshop & operational
operators who helped me in each of my work by giving me the necessary
information they have & moral support.
Last but not least I would like to say thanks for our school for giving this golden
chance to develop my skills.

Executive Summary
The major objective of internship is to reinforce and enhance the theoretical
knowledge gained in the class room with practical job experience. As we know the
real world is suitable place for seeing everything in practice and I have spent one
semester as an intern in an organization called Metal and Engineering Corporation
(METEC).
This industry is one of the small branch of Metal and Engineering Corporation
(METEC) of F.D.R.E which thrives to alleviate the burden of foreign expense
allotted to import light rail transit train and bus. This factory receives students and
assist them to upgrade their practical knowledge. This report includes the detail
information about light rail transit and production factory.
During my internship period I have participated in three projects. The projects are
drawing the factorys distribution single line diagram, design of the Fire alarm and
room ambient control system. I participated on all of the above projects but mostly
I spend my time in design of the Fire alarm and room ambient control system.
In this report the overall activities I performed, the benefits I gained, the skills I
acquire etc. are briefly presented. Generally, internship is the best opportunity to
know who I am and in order to test my own patience and skill.

List of Figures
Figure 1: Overall view of the Company-------------------------------------------9
Figure 2: Main product of the Company ------------------------------------------11
Figure 3: Structure of the Company -----------------------------------------------13
Figure 4: Work flow------------------------------------------------------------------14
Figure 5: Single line diagram -------------------------------------------------------19
Figure 6: Block diagram of digital & analog system-----------------------------25
Figure 7: Basic control system block diagram------------------------------------25
Figure 8: Block diagram of control system----------------------------------------26
Figure 9: Diagram of room ambient control --------------------------------------26
Figure 10: Microcontroller ----------------------------------------------------------27
Figure 11: Temperature sensor -----------------------------------------------------28
Figure 12: Humidity sensor ---------------------------------------------------------29
Figure 13: Servo motor --------------------------------------------------------------30
Figure 14: Schematic of the room ambient control ------------------------------31
Figure 15: Diagram of fire alarm schematic of the fire alarm-------------------33
Figure 16: Schematic of the fire alarm---------------------------------------------35

Table of Contents
Background of the Company .....................................................................................7
History...............................................................................................................7
Vision ................................................................................................................9
Mission ...............................................................................................................9
Values ................................................................................................................9
Organizational culture10
Main Product of the company .........................................................................11
Structure of the Organization...........................................................................13
Work Flow......................................................14
The Internship Experience .......................................................................................15
Single Line Diagram of the Factory...................................16
The Microcontroller & interfacing Project .....................................................23
The Room Ambient control .....................................................25
Fire Alarm System...................................................33
Challenges Faced .....................................................................................................37
Overall Benefits .......................................................................................................38
Practical skills ....................................................................................................39
Work Ethics .......................................................................................................39
Interpersonal Communication ...........................................................................39
Team play skill..........................................39
Conclusion...40
Recommendation....41
Reference.........42

Background of the company

History
The Metal and Engineering Corporation (METEC) is one of the institutions
established by the federal democratic republic of Ethiopia (FDRE)
To enable the realization of governments growth and transformation plan (GTP)
and to accelerate the ongoing transition of Ethiopia into industrialization and
becoming a middle income country. Since the establishment of METEC as a public
enterprise by the council of minister regulation number 183/2002, METEC has
tirelessly the realization of its vision, mission and objective.
The federal democratic Ethiopia metal and engineering corporation have many
branch. Those are:
Bishoftu automotive industry
Metal and fabrication industry
Adama garment engineering
Dejen aviation engineering
Hebert machine tools engineering
Gafat Armament engineering
Debre Berhan engineering
Ambo metal engineering
Zuqualla steel rolling
Legehar Locomotive sub industry

Locomotive industry of light train production factory was established in 2003E.C.

This locomotive industry was established by metal and Engineering Corporation and
Ethiopian light train office. This industry have many relation with foreign countries
like Hungary government to transfer their technology to our country.

Figure 1: overall view of the Company

Vision
Become a leading engineering company in production of light rail
transit and vehicle (bus).
To facilitate Ethiopia in industry.
To create industry linkage to the world
Establish the country as a progressive and an industrialized
through train industry.

Mission
Provide competitive engineering products of light rail transit and bus.
Play a leading role in industrialization process which aims to bring about
economic transmission of the country.
Provide transformation of technology, culture etc to foreign country.

Values
The overall activity of the company is resides on the following values.
o Trustworthiness and Reliability
o Professional excellence
o Innovativeness
o Being Scientific

Organizational Culture
The organization in general and the each member in particular has a common
culture that is useful for the success of the organization. The common cultures of
the organization are:

Democracy
Dedication
Punctuality and Responsibility
Learning and Development
Cost-effectiveness

Main products of the company

In my hosting company the products are not the same, vary as customer order such
products are
Manufacturing of light rail transit
Manufacturing of transformer cover
Manufacturing of trimeral boat
Welding of I beams for sugar corporation
Body of city bus
Note that: the raw materials are supplied from corporate companies of

Figure 2: Main products

METEC.

The factory produced a light train which was fully assembled in Ethiopia by
importing its main component from the Hungary. This train have to a 24m long
2.20m wide that is equipped with carrying capacity of 150 peoples and it has a top
speed of 60 km/hr.

The main components of the train are:

Body: the body of the train are made by RHS metal which is manufactured using
jigs and fixture.

Bogies: this bogies used for the train to move from place to place like wheel in
automobile.

Motor: this motor is the main component which is used to rotate the bogie and
the train.

Power: power is the time rate of doing work. This power is obtained from
(EELPA) as an electric current.

Pantograph: this pantograph collect an electric current from the upper cable and
gives to the transaction inverter.

Brakes: this brakes are used to stop the movement of the train using different
mechanism.

Traction inverter: which converts direct current to alternative current.

Auxiliary box: which reduce the voltage into 24 volt using step down
transformer for the purpose of lighting, opening and closing the door etc

There are 3 types of brakes in the train. These are

1. Mechanical system: this brake are used for emergency cases or sudden stops.
2. Electric system: this type of braking system is done by lowering the
pantograph from the upper cable.

3. Magnetic system: this brake use electro magnetism system to stop the motion
of the train in the station

Structure of the Company

Company is organized in main functional divisions scalable to adapt future
expansions and to enhance team spirit. Organized with scalability and flexibility in
mind METEC has managed to create a professional team capable of meeting its
stated vision and mission.

Figure 3: Structure of the Company

Work flow in light rail transit production factory

Customer order

marketing
design
planning

material

manufacturing

Painting and finishing

The final product distributed by the finance

Figure 4: Work Flow of the Company

Overall Internship Experience

How I get into the company
As an electrical engineering computer stream student, I was searching for a
company engaged on computer engineering related work. Since there are few
companies operating currently and most computer device are imported, the
window of opportunity was narrow. So UIL office takes the list of all intern
students who have not found hosting company and take the chance to choose the
top three choices of the hosting company among the available companies. I submit
my choices and the UIL office assigned me to METEC. Then the list of the
students is submitted to the hosting company.

The section of work of the intern in the company

For the first few weeks I were familiarizing myself to the compound. With the
help from the Supervisor I was able to know the general work flow, different shops
and the personals at different shop.
During the internship period I worked under the electrical division of the company
and during this time I worked on three main projects the first was designing the
single line diagram of the factory and other two projects are based on
microcontroller.
The first month on the internship looks very inspiring to work in industry. Since I
was a computer engineering student the supervisor suggested that I have to work
the first project with the other power engineering intern students. Our supervisor
told us about possible projects, out of those projects he advised as to work on the
single line diagram of the distribution not only that but also on Cable size selection
,circuit breaker .so the first project involves collected data of the distribution
boards and finally using AUTOCAD for drawing the single line diagram.

The factorys distribution system single line diagram

All sub distribution boards contain 3 phase, 380v circuit breakers.
All the boxes going out of the sub distribution contain 3 phase main circuit
breaker and may also contain 1 phase circuit breakers which comes out of
the mains.
D1 up to D8 are the main distribution boards.
AP11, AP22, AP31, and AP32 are sub distribution boards

Figure 5: single line diagram

Cable size selection once a wire or a cable type is selected based on the
mechanical, chemical and thermal strength it will be subjected to for the particular
application, the cable size is to be selected next. Refer to section 4 of EBCS-10 for
definitions and regulations related to cable. All conductors have resistance that
prevents an unlimited flow of current and of course voltage drop. For any given
load, we must select a size of conductor that limits voltage drop to a reasonable
value. Furthermore, current through a wire causes heat due to the inherent
resistance and proportional to the square of the current. There is a limit to the
degree of heat that the various types of insulation can safely withstand. Even a
bare wire must not be allowed to reach a temperature that might cause fire. Codes
specify the ampacity (the max. current-carrying capacity in amperes) that is safe
for a conductor of different sizes with different kinds of insulation and under
different operating circumstances. The size should neither be so small so as to
have a large internal voltage drop and large heat nor be too large so as to cost too
much. When selecting the size of a conductor or cable to be used in an installation
there are two main factors to be considered:
i)
The voltage drop caused by the resistance of the cable of the required
length must not exceed a limit given as a standard. Usually drops of
up to 2.5% of the supplied voltage is tolerable. For feeder cables 1%,
for branch circuits (sub circuits) 2%, and equipment taking power
directly 2.5% of the supply voltage drop is tolerable.
ii)

The wire or cable must be able to carry the maximum current liable to
flow in the circuit without undue heating. The current rating of a
conductor is defined as the maximum current it can carry continuously
without undue heating.

iii)

Cable size selection may also be affected by the operating

temperature of the cable and this should be compensated with what is
known as derating factor. iv. Cable size selection is also affected by
grouping, their spacing distance, whether they are underground or in
open air as well as insulation factors.

Cable size selection accounting increased ambient temperature

If a cable is installed in an ambient temperature of 25C and loaded with the
maximum rated current, the final temperature will be 70C. Then, if the cable is
installed at a temperature above 25C, the starting temperature of the cable will be
higher, and the running temperature will also be higher. Therefore, to prevent the
cable from overheating, we must make adjustments to the current carrying capacity
of the cable, if it is installed in an ambient temperature above 25C.
For rubber insulated conductor the maximum admissible heating up is assumed to
be reached with a temperature rise of 35OC so that the limit temperature is fixed at
25OC + 35OC = 60OC. Thermoplastics insulating materials permit an excess
temperature of 45OC giving a limit of 70OC. For instance, for a general purpose
PVC at 35C the correction factor is 0.94. This means that the cable may only be
loaded to 94 per cent of its 30C capacity. Table values of current capacities are
provided for a room temperature of 25OC and less. Typical table below relates to
temperature correction factor (Ca) for ambient temperature.

So in conclusion the following Factors affect cable size selection

The voltage drop caused by the resistance of the cable of the required length
must not exceed a limit given as a standard. Usually drops of up to 2.5% of
the supplied voltage is tolerable. For feeder cables 1%, for branch circuits
(sub circuits) 2%, and equipment taking power directly 2.5% of the supply
voltage drop is tolerable.

The wire or cable must be able to carry the maximum current liable to flow
in the circuit without undue heating. The current rating of a conductor is

defined as the maximum current it can carry continuously without undue

heating.
Cable size selection may also be affected by the operating temperature of the
cable and this should be compensated with what is known as derating
factor.
Cable size selection is also affected by grouping, their spacing distance,
whether they are underground or in open air as well as insulation factors.

After finishing the project, the supervisor told us to prepare a power point
presentation and after that to present the project to the electrical department
employs.

The Microcontroller & interfacing Project

Industrial Control Systems (ICS) allow operators to monitor and control industrial
processes, including those in the oil and gas, nuclear, power transmission and
distribution, manufacturing, chemical, and other industries. The advantage of
controlling mechanism is the devices controlling and monitoring is available in
two modes that is automatic mode and user mode.
The initiative for this project was that as a locomotive factory there was no
standard fire alarm system and a standard room ambient control system.as we all
know a fire alarm is crucial for a large scale factory .and room ambient control
system is also standard in almost all large scale factorys or industrys.
The procedures involved in implementing Room ambient control system and fire
alarm detection system by interfacing microcontroller. The process involves the
following 8 major steps shown below.

1.
2.
3.
4.
5.
6.
7.
8.

select the required sensors

find their respective datasheet of the sensors
select also other peripherals that are used in the project
model the circuit schematic diagram
design using PROTEUS simulation software
write the code for the designed circuit
link the code using PROTEUS
debug and test the code and improve the circuit

The code was written using IAR Embedded Workbench. IAR Embedded
Workbench provides an integrated development environment that allows you to
develop and manage complete application projects for embedded systems. The
environment comprises tools for compiling, linking, and debugging and they have
comprehensive and specific target support.

The circuit was designed using PROTEUS. PROTEUS was chosen because it
provides quick access to handling and managing components as well as a built in
WYSIWYG(what you see is what you get) editor which allows you to set up the
circuit as quick as possible .Proteus is a single application with many service
modules offering different functionality (schematic capture, PCB layout, etc.). The
wrapper that enables all of the various tools to communicate with each other
consists of three main parts.

The Room Ambient control

In this project I have used a low cost microcontroller to understand the various
control techniques and capabilities of sensors and implement them in real time.
Microcontroller are used in automatically controlled product and devices, such as
automobile engine control system , implantable medical devices, remote controls,
office machine, appliances, power tool.
The design of the system can be used for industrial control and monitoring. This
system is equipped with necessary hardware so as analog & digital inputs & output
can be interfaced with it.
For ease and flexibility for employing this system the software interface is
provided by programming various functional blocks in the system.

Figure 6: Block diagram of digital & analog system.

Command
+

controller
error

plant

K(s)

G(s)

_
H(s)

Feedback/sensor

Figure 7: Basic control system block diagram.

disturbance

Display unit
lcd

Sensors

Adc

Microcontroller
Heater

Lpc21xx

Drive
ckt
Fan

Figure 8: block diagram of control system.

Temperature
sensor

Motor

microcontroller

lcd
display

light
sensor

Figure 9: diagram of room ambient control

Main Components used in the circuit are

o
o
o
o
o

Microcontroller(Lpc2138)
Temperature sensor(Lm-35)
LCD screen(Lm016l)
Humidity sensor(SHT75 sensor)
Motor(Servo motor)

Microcontroller (Lpc21xx)
This is the core of the system its the main thing that makes these circuit operate
automatically.

Figure 10: Philips LPC214x series microcontroller

The advantages of this microcontroller is
Widely used IC from ARM-7
Low power consumption
Pre-loaded with many inbuilt peripherals
Multiple serial interfaces including two UART(universal asynchronous
receiver/transmitter)
Low power real-time clock with independent power and dedicated 32khz clock
input

Temperature sensor
The LM35 series are precision integrated-circuit temperature sensors, whose output
voltage is linearly proportional to the Celsius (Centigrade) temperature.

Figure 11: the lm35 temperature sensor

The advantages of the sensor is
Calibrated directly in Celsius(centigrade)
Good temperature range(-55oc 150o c)
Low-cost
Low-Impedance Output, 0.1 for 1-mA Load
Linear + 10-mV/C Scale Factor
Operates from 4 V to 30 V
Less than 60-A Current Drain
Suitable for Remote Applications
Linear + 10-mV/C Scale Factor

LCD Screen
The LCD screen used in this project is the (Lm016l) this screen is used to display
the temperature of the factory temperature.

Humidity sensor
The humidity sensor used in this project is the sht75 sensor

Figure 12: the sh75 sensor

The (SHT75 sensor) provides the following advantages
Fully calibrated
Digital output
Low power consumption
Excellent long term stability
Pin type package easy integration

Motor (servo motor)

A servo motor is an electrical device which can push or rotate an object with great
precision. If you want to rotate an object at some specific angles or distance, then
you use servo motor. It is just made up of simple motor which run through servo
mechanism. If motor is used is DC powered then it is called DC servo motor, and if
it is AC powered motor then it is called AC servo motor. We can get a very high
torque servo motor in a small and light weight packages. Due to these features they
are being used in many applications like planes, Robotics and Machine etc.

Figure 13: servo motor

Controlling Servo Motor:
Servo motor is controlled by PWM (Pulse with Modulation) which is provided by
the control wires. There is a minimum pulse, a maximum pulse and a repetition rate.
Servo motor can turn 90 degree from either direction form its neutral position. The
servo motor expects to see a pulse every 20 milliseconds (ms) and the length of the
pulse will determine how far the motor turns. For example, a 1.5ms pulse will make
the motor turn to the 90 position, such as if pulse is shorter than 1.5ms shaft moves
to 0 and if it is longer than 1.5ms than it will turn the servo to 180.

Circuit Design

Figure 14: Circuit schematic of the room ambient control

Operation of the room ambient control: Initially a temperature point is
set. The temperature sensor senses the change in input temperature .This
analog signal is after signal conditioned, is given to the analog input pin of
the micro-controller. This micro-controller converts it to digital format using
on chip ADC .If the temperature sensed is below the low limit set, the
controller unit will start the heater. Once it reaches the set limit it will switch
off the heater. If the temperature sensed is above the set limit, it will start the
blower to bring the temperature down. Once it reaches below a set point, it
will switch off the blower. In this way, temperature is controlled.

Similarly, an intensity of light can be controlled. Initially a intensity point is

set. Light dependent resistor senses the change in input intensity of light. If
the intensity of light sensed is below the low limit set, the controller unit will
switch on bulb. Once it reaches the set limit it will switch off the bulb. In
this way, intensity of light is controlled.
The LCD will provide users with the appropriate information of the
controller status or in other word it will display in real time about the status
of the temperature and the light.

Sample Source Code

The above code will be called when the temperature reaches above the
specified value, as a result it will turn on the fan and also display the status
of the fan on the LCD display.

The above code will be called when the temperature reaches below the
specified value, as a result it will turn off the fan and also display the status
of the fan on the LCD display.

Fire Alarm
Requirement:

To prevent fire damage, the factory needs a system that could give an early
warning when it detected flames and smoke. Once that information is received it
needs a way to be able to send the information to a controller and alarms and
buzzers situated throughout the factory.
Implementation:

When it comes to the implementation of fire alarm we want everything to be

automated and operate without human intervention .and also to constantly monitor
the factory.

smoke
sensor

Buzzer

microcontroller

lcd
display

Temperature
sensor

Figure 15: diagram of the fire alarm

Main Components used in the circuit are

Microcontroller(Lpc2138)
Temperature sensor(Lm-35)
LCD screen(Lm016l)
Smoke sensor(mq2 sensor)
Buzzer
Smoke sensor(MQ2 sensor)

Smoke sensor The MQ2 sensor is used for detecting smoke and also is useful for
gas leakage detection. The sensor is suitable for detecting propane, methane,
alcohol. The MQ2 sensor provides the following advantages.

Stable and long life

Wide detecting scope
Fast response and high sensitivity
Simple drive circuit

Sample Source Code

Circuit design

Figure 16: schematic design of the fire alarm circuit using Proteus

Operation of Fire Alarm This project proposes the design and construction of
fire alarm system which is controlled by of LPC 21xx.The Two LED is used to
indicate situations of the system composed of two modes of working state, critical
mode and fire mode. Graphic output states are displayed by interfacing with
microcontroller. Input signal coming from the normally opened warning device
smoke detector is sent into a detectable instrument to separate the mode of working
state. After that, output signal is dispatched to LPC 21xx microcontroller for
analysis. This microcontroller can transfer data and display the situation of the
detector. Thus the environment is exposed on the LCD. In case of fire mode, the
data will be sent to LCD and to Buzzer simultaneously. We used LM35 sensor and
using ADC to convert analog to digital and after the temperature exceeds the set
limit (say 50 degrees) the buzzer starts to buzz and if the MQ2 sensor detects
smoke that exceed the set limit it will notify the microcontroller and the
microcontroller will order to take action to the output device.

Performance Evaluation
In my view I spent my time almost focused on the internship and I was
dedicated to obtain all the things I needed to know.

Challenges Faced
The first two month of the intership was very hard for me.this is because the first
project is not related to my field of study which is computer engieering and as a
result it was challenging to study all the releated topics concerning the
project.fortunately my supervisor and the power engieering intern students helped
me.
The major problems
o Due to the lack of raw material (remember) the factory in stale of production
and I was not able to see the production process in progress.
o Most of the written materials are Chinese so it is difficult to read and
understand.
o Problem in finding the required data.
o The accurate value of the factorys load and its future growth is unknown.
o The standard used in designing the installation is unknown.
o Environmental problems are unknown.
o There are no sensors and actuators in the factory.
o There are no enough Safety protection devices.
o Some of the devices have name plate & device rating mismatch.

Measures Taken
In order to fill the gap, the only option was to refer to different books and
internet become helpful tool. Our supervisor and working fellows are also very
helpful and they were ready to support as in any way they can by answering our
question and referring as books.

Overall Benefit
During my four month internship period I gather a lot of benefit which can be seen
from different angles. It may be difficult to list the overall benefits I acquire during
my internship period within this report but the generalized thing is presented in this
report as follows.
The overall benefits I acquire in during the internship period can be classified as:
1. Practical skills
2. Work Ethics
3. Interpersonal communication skills and teamwork skills

Practical skills
Though I didnt gain much practical skill as I anticipated I still manage to learn
about the factory power distribution, factors affecting cable size selection and
breaker size.

Interpersonal Communication Skills

In terms of building a good interpersonal relationship I was able to communicate
with all the staff members for the reason that there was a friendly and welcoming
environment in the company. This has made me to easily socialize with all of them.

Team playing skill

Since I spend most of my internship period on projects so I was able to do my
projects and discussing on unclear concepts together with my fellows.

Work Ethics related issues

I have understood that a worker in a company must be committed to his job
including being at office on time, effectively working on the working time and
leaving the office on the specified time.

Conclusion and Recommendation

Conclusion
During the internship period I did get the opportunity to participate on some
projects. During my time in METEC I participate on three projects: the first being
drawing the factorys distribution system single line diagram and the other two are
interfacing projects. Even if I am assigned to work on the above three projects, I
spend most of my time on interfacing projects.
During my time I worked under the electrical department where I did three projects
the first being drawing the factorys distribution system single line diagram and the
other two are interfacing projects.
The first project involves drawing the factorys distribution system single line
diagram and also to prepare a guidance document on the application of the
improved methodology for general use of the factory.
The second project was an interfacing project titled room ambient control system.
The goal of the project was the lack of automatic light and temperature control
system.so the project resolves this problem by designing a temperature and light
controller using lpc21xx microcontroller, temperature and light sensor.
The third and final project is also an interfacing project. The goal of the project
was the lack of automatic fire alarm in the factory.so the project resolves this
problem by designing a fire alarm using the lpc21xx microcontroller, temperature
sensor, smoke sensor and an alarm (Buzzer).

Recommendation
During my four month internship even if I have done some projects, the only thing
I hear is the sound of soldering and most of the time the Company is idle. So this
must have to be changed by working with other Company with joint venture and
taking other Companies experience is crucial for the Company future growth.
If METEC allows interns to participate on real projects that are currently not done,
it may be advantageous for both the company and interns. Interns may get a chance
of looking and taking part on real projects and may help to grasp a huge amount of
knowledge from professionals. On the other side the company may get advantage
of materializing the skills of the interns. But as we observe in METEC most of the
projects are not real projects rather they are planned to be done for the future.
METEC must take measures to circumvent problems that the Factory is currently
facing. The major problem I saw is the departments are not currently doing their
jobs as planned. They look good on paper but practically there is nothing.
The Interns must be placed based on their stream placement and interest
i.e. Software development, hardware, communication, control, etc.
Interns must be participate on real projects and must be paid pocket money by the
Company.

Reference
https://www.metec.gov.et/
https://www.wikipedia.com/