SlideShare a Scribd company logo
1 of 51
Download to read offline
i
National Apprentice & Industrial Training
Authority
Report on Industrial Training
At
CBL FOODS INTERNATIONAL (PVT) LTD
HABARAKADA ROAD,
RANALA,
University Collage of Rathmalana
Rathmalana
Name : B.A.D.Idumal
Student Number : RT/ECT/17/0003
Course : Higher National Diploma in Electrical Technology
Field : Electrical
Period : 06 months
i
ACKNOWLEDGMENT
First of all, I would like to offer my sincere gratitude to the Industrial Training Division of University
collage of Rathmalana, National Apprentice and Training Authority (NAITA) and also CBL Foods
International (Pvt) Ltd for giving me this opportunity to enhance my technical knowledge.
I would like to thank Our Lecture and student coordinator Mr. Prabhath Sanjeewa Herath and all the
staff members of Industrial Training Division of University collage of Rathmalana & Industrial Training
Authority (NAITA). organizing such a valuable industrial training program for us. Without them I
won't be able to get such a valuable training experience. Then I would like to convey my gratitude to
Further, I would especially like to thank to the training manager of CBLF and the HR Executive of
CBLF for giving the training opportunity and introduction to the factory environment. Also, I would like
to thank head of electrical engineers and other all Engineers, Supervisors and Technicians for their great
support.
Last, I want to offer my gratitude to all others who may have forgotten to mention above for their great
support to me. I sincerely thank all colleagues who assisted me in every possible way to make industrial
training a success.
B.A.D.Idumal
Higher National Diploma,
Department of Electrical Technology,
University Collage of Rathmalana.
ii
PREFACE
In this report, the experience and knowledge that I have gained during my first industrial training
program has been included. The way faced and handled the encountered problems and the solutions
given to them have been included in this report. The first industrial training was at CBL FOODS
INTERNATIONAL (PVT) LTD, Ranala from 08th January to 7th July 2019.
During these 6 month of training period, I was able to interact with real engineering experience and also
it helped to acquire additional theoretical knowledge about industrial applications. In this report, there
are mentioned all the knowledge and working experience that have been obtained during this limited
time period.
This report is consisted of mainly 3 major chapters. First chapter mainly includes Information about
Training Establishment. Then First chapter describes main functions, Organizational chart, Nature of
business and Vision, Mission, Management style, Present Performance and safety practices.
The second chapter mainly describes training experience at the Training Establishment, it contains about
the technical experience and provides the information about the projects I have done during the training
period, in Head office, workshop and plants area.
The third or final chapter includes the conclusion of the report. This conclusion includes an assessment
on the current Industrial Program.
iii
Table of Content
1 INTRODUCTION TO THE TRAINING ESTABLISHMENT..........................1
1.1 HISTORY OF THE CEYLON BISCUIT LIMITED........................................................................... 1
1.1.1 Nature of Business .......................................................................................................... 1
1.1.2 Departments of The Company.......................................................................................... 3
1.1.3 Production Plants of the Company.................................................................................... 3
1.1.4 Organizational chart ......................................................................................................... 4
1.2 CO – OPERATE PLAN.............................................................................................................. 5
1.2.1 Vision .............................................................................................................................. 5
1.2.2 Mission ............................................................................................................................ 5
1.3 MANAGEMENT PRACTICES .................................................................................................... 5
1.3.1 Recruitment Procedure..................................................................................................... 7
1.4 PERSONAL PROTECTIVE EQUIPMENT (PPE)............................................................................ 9
1.4.1 Safety Equipment............................................................................................................. 9
1.4.2 Electricalsafetysymbols.................................................................................................... 11
1.4.3 Electrical Safety clothing................................................................................................ 12
2 TRAINING EXPERIENCE................................................................................13
2.1 AC POWER DISTRIBUTION................................................................................................... 14
2.1.1 Single phase wire system................................................................................................ 14
2.1.2 Three phase wire system ................................................................................................ 14
2.1.3 Type of wire with their current carried capacity.............................................................. 15
2.1.4 Cable Wire Protection .................................................................................................... 15
2.1.5 DDLO (Drop Down Lift On).......................................................................................... 16
2.2 WHAT IS EARTH FAULT....................................................................................................... 18
2.2.1 How Earth Fault Protection Devices working ................................................................. 18
2.2.2 Earth Fault Relay (EFR)................................................................................................. 18
2.2.3 Earth Leakage Circuit Breaker........................................................................................ 18
2.2.4 Ground Fault Circuit Interrupter..................................................................................... 19
2.2.5 Restricted Earth Fault Protection Scheme ....................................................................... 19
2.2.6 Short Circuit Protection Devices..................................................................................... 20
2.2.7 Fuse ............................................................................................................................... 20
2.2.8 Circuit Breaker............................................................................................................... 20
2.3 A MOLDED CASE CIRCUIT BREAKER (MCCB)..................................................................... 21
2.3.1 The Operates of MCCB.................................................................................................. 21
iv
2.4 MOTOR PROTECTION CIRCUIT BREAKER (MPCB)................................................................ 22
2.5 CONTACTOR ....................................................................................................................... 24
2.5.1 Inside of Contactor Coil ................................................................................................. 25
2.6 RELAY................................................................................................................................ 27
2.6.1 Design of relay............................................................................................................... 27
2.7 ENCODER............................................................................................................................ 27
2.7.1 Linear encoder ............................................................................................................... 28
2.7.2 Rotary Encoder .............................................................................................................. 28
2.7.3 Incremental Encoder ...................................................................................................... 29
2.7.4 Absolute encoders .......................................................................................................... 29
2.8 INDUCTIVE SENSOR ............................................................................................................. 30
2.9 VFD (VARIABLE FREQUENCY DRIVE) ................................................................................. 31
2.9.1 Advantage of VFD ......................................................................................................... 35
2.9.2 Application of VFD........................................................................................................ 35
2.10 METAL DETECTOR............................................................................................................... 36
2.11 PROGRAMMABLE LOGIC CONTROLLER (PLC)...................................................................... 37
2.11.1 PLC Architecture........................................................................................................ 38
2.11.2 CPU Module: ............................................................................................................. 38
2.11.3 Power Supply Module: ............................................................................................... 38
2.11.4 I/O Modules: .............................................................................................................. 38
2.11.5 Communication Interface Modules:............................................................................ 38
2.11.6 Application of PLC automation system....................................................................... 40
3 CONCLUSION TO THE REPORT...................................................................41
4 REFERENCE ......................................................................................................42
List of Table
TABLE 1 - SAFETY SYMBOLS............................................................................................................... 11
TABL2 - CURRENT CARRIED CAPACITY............................................................................................... 15
v
Table of Figure
FIGURE 1 - CEYLON BISCUIT LIMITED (1968)........................................................................................ 1
FIGURE 2 - CBL GROUP OF COMPANIES ................................................................................................ 1
FIGURE 3 - CBL FOODS INTERNATIONAL (PVT) LTD............................................................................. 2
FIGURE 4 - CBL LOGO.......................................................................................................................... 2
FIGURE 5 - LOCATION OF THE COMPANY............................................................................................... 2
FIGURE 6 - MANAGEMENT HIERARCHY OF THE ENGINEERING DEPARTMENT .......................................... 3
FIGURE 7 - ORGANIZATIONAL CHART.................................................................................................... 4
FIGURE 8 - COOPERATE VISION AND MISSION ....................................................................................... 5
FIGURE 9 - SAFETY HELMET ................................................................................................................. 9
FIGURE 10 - SAFETY GOOGLES.............................................................................................................. 9
FIGURE 11 - SAFETY SHOES .................................................................................................................. 9
FIGURE 12 - EAR MUFFS..................................................................................................................... 10
FIGURE 13 - ELECTRICAL GLOVES....................................................................................................... 10
FIGURE 14 - SAFETY CLOTHING........................................................................................................... 12
FIGURE 15 - WIRING SYSTEM TYPES ................................................................................................... 14
FIGURE 16 - OLD WIRE AND NEW COLOR CODE ................................................................................... 14
FIGURE 17- OLD WIRE AND NEW COLOR CODE.................................................................................... 15
FIGURE 18 - CABLE WIRE INSULATION................................................................................................ 15
FIGURE 19 - DDLO (DROP DOWN LIFE ON)........................................................................................ 16
FIGURE 20 - FUSE LINK....................................................................................................................... 17
FIGURE 21 - FUSE LINK....................................................................................................................... 17
FIGURE 22 - EARTH FAULT RELAY...................................................................................................... 18
FIGURE 23- EARTH FAULT PROTECTION WITH ..................................................................................... 19
FIGURE 24 - FUSE ............................................................................................................................... 20
FIGURE 25 - MOLDED CASE CIRCUIT BREAKER (MCCB)..................................................................... 21
FIGURE 26 - MPCB ............................................................................................................................ 22
FIGURE 27 - CONTACTOR.................................................................................................................... 24
FIGURE 28- CONVENTIONAL LAMINATED SOFT IRON MAGNETIC CORE................................................. 24
FIGURE 29- CONVENTIONAL LOW VOLTAGE CONTACTOR COIL/ CONVENTIONAL LOW VOLTAGE
CONTACTOR COIL SOLID STEEL CORE.......................................................................................... 25
FIGURE 30 - INSIDE WORKING OF CONTACTOR ..................................................................................... 26
FIGURE 31 - RELAY ............................................................................................................................ 27
FIGURE 32 - ENCODER ........................................................................................................................ 27
FIGURE 33- LINEAR ENCODER............................................................................................................. 28
FIGURE 34 - ROTARY ENCODER .......................................................................................................... 29
vi
FIGURE 35- INCREMENTAL AND ABSOLUTE ENCODER ......................................................................... 29
FIGURE 36 - INDUCTIVE SENSOR ......................................................................................................... 30
FIGURE 37- INDUCTIVE PROXIMITY SENSOR......................................................................................... 30
FIGURE 38 - SHIELDED AND UNSHIELDED SENSORS.............................................................................. 31
FIGURE 39- VARIABLE FREQUENCY DRIVE.......................................................................................... 31
FIGURE 40- VFD DIAGRAM................................................................................................................. 32
FIGURE 41.......................................................................................................................................... 32
FIGURE 42 - RECTIFIER OUTPUT WAVE ................................................................................................ 33
FIGURE 43- REAL VFD, THE SWITCHES SHOWN WOULD ACTUALLY BE TRANSISTORS. ........................... 34
FIGURE 44- THE BLUE SINE-WAVE IS SHOWN FOR COMPARISON PURPOSES ............................................ 34
FIGURE 45- METAL DETECTOR ........................................................................................................... 36
FIGURE 46- EDDY CURRENTS INDUCE THEIR OWN MAGNETIC FIELD ...................................................... 36
FIGURE 47- INDUCES A MAGNETIC FIELD ............................................................................................. 36
FIGURE 48- PROGRAMMABLE LOGIC CONTROLLER (PLC) ................................................................... 37
FIGURE 49- PLC ARCHITECTURE ........................................................................................................ 38
FIGURE 50- PLC SCAN CYCLE ............................................................................................................ 39
1
1 Introduction to the Training Establishment
1.1 History of the Ceylon Biscuit Limited
William’s Biscuit Factory, the first biscuit factory in Sri Lanka was a small scale handmade biscuit
venture owned by Mr. Williams. This factory was acquired in 1939 by Mr. Simon Arthur
Wickramasingha and launched “Williams Confectionery” with just 10 employees. It was mechanized
with Baker Perkins lines in 1957.
Together with the Sri Lankan Government and CARE of USA, high-protein biscuits were manufactured
by ‘Williams’ to supplement mid-day meals for school children of Sri Lanka. A biscuit factory was built
for this purpose on eight acres of rubber land in Pannipitiya in 1968. The factory was operated by Ceylon
Biscuits Limited (CBL)
It launched its own brand name “Munchee”, which gradually invaded the biscuit market in late 1990s.
(Ceylon Biscuits Limited, 2002) CBL has now become one of the largest privately-owned business
groups of Sri Lanka with the inception of number of subsidiaries, which extended its territory in the food
market. It now has gained a firm grip of the local market and an excellent global presence.
1.1.1 Nature of Business
Figure 2 - CBL Group of Companies
Figure 1 - Ceylon Biscuit Limited (1968)
2
CBL Foods International (PVT) Limited, is one of the best subsidiaries of the CBL Group which is a
major foods manufacturing company in Sri Lanka incepted in 2002. It manufactures a range of
confectionery products (rice cracker, chocolates, biscuits, wafers, cakes) under the brand names of
Ritzbury, Munchee, Tiara and Kome. It is located on 200,000 square foot of land at Ranala, just 20 km
away from the city of Colombo.
Employee Strength of CBL Foods International (PVT) Ltd.
• Total Employee: - 1200
• Direct Employee: - 400
• Manpower Employee: - 800
Figure 3 - CBL Foods International (PVT) Ltd
Figure 4 - CBL Logo
Figure 5 - Location of the Company
3
1.1.2 Departments of The Company
There are 12 departments in CBL Foods International (PVT) Ltd which collectively contribute in goal
achieving process. They are,
• Production Department
• Human Resources Department
• Stores Department
• Supply Department
• Engineering Department
• Quality Assurance Department
• Projects and Safety Department
• Marketing and Sales Department
• Information Technology Department
• Exports Department
• New Product Development Department
• Work Study Department
1.1.3 Production Plants of the Company
There are 06 production plants in the establishment. They are,
• Biscuit Plant
• Rice Cracker Plant
• Wafer Plant
• Cake Plant
• Chocolate Plant
• Candy Bar Plant
Figure 6 - Management Hierarchy of the Engineering Department
4
1.1.4 Organizational chart
CBL Foods International (PVT) Ltd organizational hierarchy starts with Mr. Ramya Wickramasingha,
The CBL group’s Chairman, The board of directors of the CBL group and the CEO of CBL Foods,
Chairman
Deputy Chairman
Board of Directors
Chief Executive Officer
GM
F & A
AGM –
WH &
Log
Mgr. -
Sup
Head of the
Department of
Quality Assurance
QA Manager
QA Executives
QA Assistants
QA Helpers
Lab & Microbiology Manager
Microbiological
analyst
Mgr.
R&D
HRM
Mgr.
Project
Dev. &
Safety
Mgr.
Prem. is
&
environ.
Snr.
Eng.
Pro.
GM
P & E
Eng.
Asst.
Eng.
Mech
anics
Factory
Mgr.
Prod
Mgr.
Floor
level
work
Figure 7 - Organizational Chart
5
1.2 Co – operate plan
1.2.1 Vision
CBL groups’ collective vision is “to become the market leader in confectionary, in South Asia with a
global presence and recognition”.
1.2.2 Mission
A CBL group of company has no a clear stated mission rather achieving the marketing goals set for each
product with the aid of company assets and the latest innovation and technology.
1.3 Management Practices
SWOT Analysis is a useful technique for understanding Strengths and Weaknesses, and for identifying
both the Opportunities open and the Threats in a project or a business venture.
Strengths
• Strong cooperative top management
• Highly educated and capable staff with skills
• Well trained and motivated junior staff and confident third-party employees.
• Well established sales and distribution network in local and international market.
• Strong brand images and “excellent sales force”
• Enterprise Resources Planning systemized with SAP which enable the
• management to have a better look on the plant performance.
• Capability of doing research and development of products
• Approach to minimize the frequency of breakdowns
• Approach to increase energy and chemical saving.
Figure 8 - Cooperate Vision and Mission
6
Weaknesses
• Dependence on single suppliers for critical raw material (Wheat flour)
• Low profit margins of some products
• nobility to meet demand and inability of expanding the volume in some products due to
• limited machinery availability and less employees.
• Limited land availability
• High wastage in some products
• Water consumption per unit volume of product is high.
• Unavailability of training personals due to their huge amount of work load.
Opportunities
• Rapidly Expanding Export Market
• Growing of economy in Sri Lanka
• Product Diversification
• One of a key confectionary manufacture in Sri Lanka
• Social influence
Threats
• Upcoming of competitors due to the inability of increment of production capacity with the
demand fluctuation.
• Information Technology Consulting Agreement (ITCA) with India.
• Capability of global players entering the market capturing the chocolate market.
• Price competition for high price sensitivity products in local market.
• Upcoming of rivals with local formulas which attracts the local customers than the international
formulas now applied in many products.
Contribution to the Sri Lanka Society
CBL Foods serves the country as the leading bakery and confectionery factory since 2002. For more
than a decade, they have been manufacturing biscuits, chocolate and other products identifying
consumer’s needs and wants while enriching the nation with their nutritional bakery products. Around
1200 people are employed in the factory including both company and man power workers. Other than
man power, lot of services has been outsourced by the company which creates many more job
opportunities indirectly.
As a social responsibility, the CBL group conducts and sponsors in several educational, sports, art and
7
cultural events frequently. Providing the training opportunities such an event which enables the
establishment to transfer their technology, experience and knowledge to the future work force of Sri
Lanka.
Administrative Practices
Leave Structure
• Annual leaves 14
• Casual leaves 7
1.3.1 Recruitment Procedure
When required an employer for relevant division, the division manager inform to HR division. HR
division should be publishing an application and the candidate ready to face relevant interview. The
interview is conducting by structured interview panel. The interview is done by providing relevant field
questionnaire, practical problems and evaluating past experience of the candidate.
1.3.1.1 Employees’ Provident Fund (EPF)
The employees’ Provident Fund (EPF) the employees provident fund scheme basically covers almost all
the employees in the private sector and the cooperation sectors. The main objective of this scheme is to
provide social security or protection to employee at old stage inactivity or their dependent after death.
All employees are registered under government approved EPF. 8% of the employee’s salary and 12%
contributed by company will be remitted to the central Bank of Sri Lanka Employees’ Provident Found.
Every employee contributing to the EPF is assigned a membership number.
1.3.1.2 Employees’ Trust Fund (ETF)
The employees trust fund is administrated by the employees Trust Fund Board and at present the ETF
board is functioning under the Ministry of Finance. The company will contribute an amount 3% of the
employees’ salary to employees’ Trust Fund
8
1.3.1.3 Safety Practices
Safety of the employers is the most critical aspect in industries. The management should be able to
confirm the safety of the labors and the all staff with same attention to all. Safety analysis should be
done before each activity and maintenance activities. In addition to that each of the people currently
employing inside the factory should be aware of the safety precautions and the emergency actions that
should be taken at relevant occasion.
The advantages of good safety environment are prevention of deaths, injuries, financial losses and
property damage, increasing worker productivity, enhancing product or service quality and promoting
good public relations and etc.
1.3.1.4 Lockout-Tag out concept
Lockout-tagout (LOTO) or lock and tag is a safety procedure used in industry and research settings to
ensure that dangerous machines are properly shut off and not able to be started up again prior to the
completion of maintenance or repair work. The LOTO concept is used in most branded companies in
their premises and maintain it as their own standard. In this concept it ensures a safety and a protection
for the labors, technicians and for the processes of the company. In industry it turns a higher
consideration on LOTO concept and it is a must in some countries since the safety is first in all the time.
In the CBL Foods International, Ranala uses this concept for their maintenance. The Lockout-tagout
procedure is as follows.
• Announce shut off
• Identify the energy source
• Isolate the energy source
• Lock and tag the energy source.
• prove that the equipment isolation is effective
9
1.4 Personal Protective Equipment (PPE)
safety is the first thing in the industry. Proper safety equipment is helped to prevent any kind of damages.
General Safety Equipment
1.4.1 Safety Equipment
• Safety Helmet: It is used as a protection against injuries to a head, from falling or flying objects
• Safety Goggles: It is used as a protection to the eye. While working in dusty places, the right type goggles
should be used.
• Safety Shoes: safety shoes were used for the protection of legs from injury.
Figure 9 - Safety Helmet
Figure 10 - Safety Googles
Figure 11 - Safety Shoes
10
• Ear plugs/ Ear muffs: Hazardous noise in generator rooms, grinding areas, production areas
• Electrical gloves are required when working in high and low voltage applications to protect
workers from shock, burns, fires and explosions.
Figure 12 - Ear Muffs
Figure 13 - Electrical Gloves
11
1.4.2 Electrical safety symbols
Table 1 - Safety Symbols
signs and symbols Description
Voltage Warning Labels
Danger of death from electricity warning
Switch off when not in use
Electric shock warning
Danger do not enter sign
Warning to isolate before removing cover
safety helmet must be worn sign
12
1.4.3 Electrical Safety clothing
All electrician, and employees must understand and comply with safety standards related to electrical
work and follow the uniform practices outlined in this document when engaged in electrical work. Here
show what the Electrical safety clothing in workplace are,
Figure 14 - Safety clothing
13
2 Training Experience
I trained at Electrical department of CBL International PVT Ltd. During this 6-month implant training
period I got lot of technician level and supervisor Level experience in transmission and distribution,
motor controller, generator servicing, UPS system maintenance, wiring diagram inspection,
Switchgears, testing…etc. First day of the training I was able to learn about safety instructions and
introduction and identify tools in workshop.
In the workshop, I learned about panel designing, Power Distribution System and wiring panel board
according to the job requirement. And also, when I was in training period I have done some projects
related to Compressed Air Energy Conservation, and Electrical and Electronics Equipment Repairing
and Servicing Record, General Electrical Audit report, Etc.
while I was in my training period I got lots of working experience with other Electricians but sometime
working with them make was a little harder for me. But however, I was able to manage everything in a
proper manner.
Basically, electrical department is doing repair and maintenance on all of the electrical parts in the
machineries and they also maintenance and service the power distribution system around the company.
All the plants have various kinds of machinery and conveyor lines which use the best of technology that
available. European machinery for manufacturing and Japanese machinery with very accurate weight
control for packaging. Also there were fully automated continuous manufacturing process within a
highly controlled environment. Especially in cake production plant, they use fully automated continuous
manufacturing process with a class 100,000 clean room. Cakes are devoid of human contact during
production and completely isolated from exterior environment. Most of the productions in the company
are fully autonomous and others are being automated as well.
In the complete training period I was able to learn about how to interact with colleagues and how to deal
with the chain of command. I also observed about how the Electrical department operate, Which
Individuals are responsible and equipped with dealing with specific tasks. In a company there are
different peoples with different abilities and talents. As a Supervisor We need to be able task them with
work that they are good at.
14
2.1 AC Power Distribution
2.1.1 Single phase wire system
It is easier to balance the electrical loads of the network. single-phase connection, two wires come into
your electrical service panel. There was standard color code. In single phase wiring system wire color
changed since 2006, live cable to Brown and Neutral Cable to Blue color. Single phase wiring system
mainly used in home appliances.230V phase voltage between (N) neutral live and (L) live wire.
2.1.2 Three phase wire system
Three phase system is more suited to the consumption of a building that includes powerful machines.
three-phase connection, 3 or 4 wires come into your electrical service panel. Most of the time, a voltage
difference of 230 V separates each live wire from the neutral, while there is a voltage difference of 400
V between two live wires. This makes it possible to supply both the domestic cables with 230 V and
machines requiring 400v.
• Industrial use only
• in three phase wiring system there were
two methods.
• Three wire method for motors and Four
wire method for panel board wiring.
Figure 15 - Wiring System Types
Figure 16 - Old wire and New color code
15
2.1.3 Type of wire with their current carried capacity.
Tabl2 - Current Carried Capacity
Area (in mm2
) Current carrying capacity ( in
Amp)
Number of wire and thickness
of each wire
1 11 1/0.044
1.5 13 3/0.024
2.5 16 3/0.036
4 21 7/0.029
6 28 7/0.36
10 34 7/0.44
16 43 7/0.052
25 56 7/0.064
35 66 7/0.044
2.1.4 Cable Wire Protection
Figure 17- Old wire and New Color Code
Figure 18 - Cable Wire Insulation
16
1 - PVC jacket -
Cable jacket is the first line of moisture, mechanical, flame and chemical defense for cable.
2 - braid shield -
Braided shielding is a type of shielded cable that uses a tightly woven lattice of thin tin or copper wires
to encapsulate a shielded cable assembly.
3 - Aluminum Mylar –
This is used to protect the conductors from external frequencies. The shield also helps ==089keep in
continuous contact with the drain wire. The drain wire picks up unwanted electricity and grounds, it.
4 – PVC insulation -
PVC insulated wires have become so popular among electrical industries is because they are highly
versatile
5 – Conductor –
Conductor or group of conductors for transmitting electric power or telecommunication signals from
one place to another
6 – Drain wire
Drain wire is a part of a shield within a cable that reduces the resistance from any point on the shield to
ground
2.1.5 DDLO (Drop Down Lift On)
While I am in my training period. I could get experience with DDLO.it is a device that uses to protect
Transformers, capacitor banks or electrical devises from high current surges and can consider it as a
combination of fuse and a switch. This can provide a wide range of protection for overhead distribution
system rated from 10kV to 36kV. Always DDLO connects in series with the transition line. For DDLO,
standard voltage ratings are maintained between 11/12 kV ,22/24 kV ,33/36 kV. Fuse cutouts are capable
of carries a maximum current of 100 A to 200A.
Figure 19 - DDLO (Drop Down Life On)
17
2.1.5.1Positioning of the DDLO
In Sri Lanka CEB practice is to position the DDLO before the Arresters along the high voltage circuit.
(As shown in figure A) This concept ensures the safety of the workers who work on the transformer
during the maintenance. (As the arrester is isolated when DDLO switch is opened)
Figure 20 - Fuse Link
Figure 21 - Fuse Link
18
2.2 What is Earth Fault
Earth Fault is an inadvertent fault between the live conductor and the earth. When earth fault occurs, the
electrical system gets short-circuited and the short-circuited current flows through the system. The fault
current returns through the earth or any electrical equipment, which damages the equipment. It also
interrupts the continuity of the supply and may shock the user. To protect the equipment and for the
safety of people, fault protection devices are used in the installation.
2.2.1 How Earth Fault Protection Devices working
The devices give the tripping command to break the circuit when earth fault occurs. The fault current is
restricted and the fault is dispersed by the Restricted Earth Fault Protection (REFP) scheme. Normally
earth fault relay, earth leakage circuit breaker and ground fault circuit interrupter, etc. are used to restrict
the fault current.
2.2.2 Earth Fault Relay (EFR)
It is a safety device used in electrical installations with high earth impedance. It detects small stray
voltages on the metal enclosures of electrical equipment. The result is to interrupt the circuit if a
dangerous voltage is detected. The EFR is protected against tripping from transients and prevents shock.
2.2.3 Earth Leakage Circuit Breaker
The Earth Leakage Circuit Breaker detects the leakage current directly and prevents injury to humans
and animals due to electrical shock. It is a voltage-sensing device and has recently been replaced by
Residual Current Circuit Breaker (RCCB), which is a current sensing device. It is a special type of
latching relay that is connected to the main power supply. When the fault current flows from live wire
to the earth wire within the installation, the coil of ELCB senses the voltage and switches off the power.
This requires a manual reset process to work again. The RCCB senses the leakage current and sends a
signal to trip the system.
Figure 22 - Earth Fault Relay
19
2.2.4 Ground Fault Circuit Interrupter
The Ground Fault Circuit Interrupter is a safety device to prevent an electrical accident when any faulty
tool is plugged in. It is a fast-acting circuit breaker to shut down the supply when the earth fault occurs
within 1/40th of a second. It compares the incoming and outgoing current from the equipment along the
circuit conductor. If there is any difference as little as 5 mA, GFCI restricts the current and trip quickly.
GFCI does not help much with line contact hazards but protects from fire, overheating and destruction
of wire insulation
2.2.5 Restricted Earth Fault Protection Scheme
A star winding transformer, which is protected by a Restricted Earth Fault Protection with EFR
protecting device as shown in the figure below.
When an external fault F1 occurs in the network, I1 and I2 flow through the secondary side of the CTs.
The resultant of I1 and I2 will be zero. However, if an internal fault F2 occurs inside the protective zone,
only I2 flows and I1 is neglected. The resultant current I2 passes through the earth fault relay, which
senses the fault current and protects the restricted portion of winding. The fault current is approximately
15% more than the rated winding current. To avoid the magnetizing inrush current, the stabilizing current
must be in series with the relay.
Figure 23- Earth Fault Protection with
20
2.2.6 Short Circuit Protection Devices
To protect the devices and people from short circuit hazards, protecting devices are used in electrical
circuits. These devices can detect the faults and trip the circuit immediately before the surge current
reaches to the maximum. There are two popular protecting devices used frequently in every electrical
circuit in industrial, let see in CBL.
2.2.7 Fuse
Fuse is operated once in the circuit and then must be replaced after the trip occurs. It is helpful for phase
by phase (single pole) protection. It offers a high breaking capacity at low volume, which limits electro-
dynamic stress.
2.2.8 Circuit Breaker
Circuit breakers can be reset either manually or automatically. It automatically breaks the circuit within
a short cutoff time and separates the load from the power supply that protects the circuit from any
damage. The magnetic triggers of CB open the poles. CBs limit both the thermal and thermodynamic
effects. It works faster than a fuse. For example, Molded Case Circuit Breaker (MCCB), , Vacuum
Circuit Breaker
Figure 24 - Fuse
21
2.3 A Molded Case Circuit Breaker (MCCB)
It is a type of electrical protection device that is used to protect the electrical circuit from excessive
current, which can cause overload or short circuit. With a current rating of up to 2500A, MCCBs can be
used for a wide range of voltages and frequencies with adjustable trip settings. These breakers are used
instead of miniature circuit breakers (MCBs) in large scale PV systems for system isolation and
protection purposes.
2.3.1 The Operates of MCCB
The MCCB uses a temperature sensitive device (the thermal element) with a current sensitive
electromagnetic device (the magnetic element) to provide the trip mechanism for protection and isolation
purposes. This enables the MCCB to provide:
1) Overload Protection,
2) Electrical Fault Protection against short circuit currents, and
3) Electrical Switch for disconnection.
Figure 25 - Molded Case Circuit Breaker (MCCB)
22
2.3.1.1Overload Protection
Overload protection is provided by the MCCB via the temperature sensitive component. This component
is essentially a bimetallic contact: a contact which consists of two metals that expand at different rates
when exposed to high temperature. During the normal operating conditions, the bimetallic contact will
allow the electric current to flow through the MCCB. When the current exceeds the trip value, the
bimetallic contact will start to heat and bend away due to the different thermal rate of heat expansion
within the contact. Eventually, the contact will bend to the point of physically pushing the trip bar and
unlatching the contacts, causing the circuit to be interrupted.
The thermal protection of the MCCB will typically have a time delay to allow a short duration of
overcurrent which is commonly seen in some device operations, such as inrush currents seen when
starting motors. This time delay allows the circuit to continue to operate in these circumstances without
tripping the MCCB
2.3.1.2 Electrical Fault Protection against short circuit currents
MCCBs provides an instantaneous response to a short circuit fault, based on the principle of
electromagnetism. The MCCB contains a solenoid coil which generates a small electromagnetic field
when current passes through the MCCB. During normal operation, the electromagnetic field generated
by the solenoid coil is negligible. However, when a short circuit fault occurs in the circuit, a large current
begins to flow through the solenoid and, as a result, a strong electromagnetic field is established which
attracts the trip bar and opens the contacts.
2.4 Motor Protection Circuit Breaker (MPCB).
Figure 26 - MPCB
23
In industrial MPCB are very important, so I got lot of experiences with when panel board wiring. Motor
protection circuit breakers are a specialized type of electrical protection device that is designed
specifically for electric motors, like their name implies. Electric motors have plenty of applications and
are used to drive mechanical devices of all types, so it is very important to protect them adequately with
MPCBs. The following are just a few examples of devices driven by electric motors in commercial and
industrial buildings:
• Rooftop air conditioners, chillers, compressors, heat pumps and cooling towers.
• Extraction and injection fans, as well as air handling units.
• Water pumping systems.
• Elevators and other hoisting devices.
• Industrial conveyor belts and other machinery used in manufacturing processes.
The working condition of MPCB. It has bi-metallic strips in all three phases which gives overload
protection. The bi metallic strip bends when current passing through increases from rated current due to
heat generated by over current. The bending of bi metallic strip operates tripping mechanism of Circuit
breaker.
For short circuit protection it has electromagnetic coil. When current ratings increase say in kA ratings,
the coil gets magnetized and hence the plunger pulls in which in turn operates the tripping mechanism
of circuit breaker.
24
2.5 Contactor
Contactors are very common things I have seen every panel board. Basically, contactor is an electrically-
controlled switch used for switching an electrical power circuit. A contactor is typically controlled by a
circuit which has a much lower power level than the switched circuit, such as a 24-volt coil
electromagnet controlling a 230-volt motor switch. A contactor consists of an electromagnet, contacts
and spring enclosed inside an enclosure. In some contactors, economizers are provided to reduce power
consumption. Certain arrangements for arc extinction is also made inside for making and breaking the
operation of contactors.
Figure 27 - Contactor
Figure 28- Conventional laminated soft iron Magnetic Core
25
2.5.1 Inside of Contactor Coil
An electromagnet is a key component in contactors without which it cannot function. It requires an
additional supply for excitation. It drains negligible current from the supply during excitation. These
electromagnets will be hollow cylindrical in shape. A rod (armature) with spring return arrangement will
be placed in the hollow cylindrical electromagnet. In some contactors, this electromagnet is split into
two halves. One of the halves is fixed and the other is movable. Movable power contacts are fixed to the
movable electromagnet. Under normal condition, these two halves of electromagnets are held apart using
spring in between. In contactor with AC coil, the electromagnetic core is made up of laminated soft iron
to reduce eddy current losses and in contactor with DC coil, the electromagnetic core is made up of solid
steel/ soft ironic core since there is no risk of eddy current loss in DC. Working Condition of Contactor
A contractor is very simple. Whenever the electromagnetic coil is energized, an electromagnetic field is
produced. This electromagnetic field attracts the metallic rod (armature) towards the gap in the hollow
cylindrical magnet. In contactors with split electromagnets, the movable half of the electromagnet is
attracted towards the fixed electromagnet. This action closes the contacts. The contacts remain closed as
long as the electromagnet remains excited. When the coil is de-energized, moving contact is pushed back
to its normal position by the spring. Contactors are designed to open and close contacts rapidly. Moving
contacts may bounce as it rapidly makes contacts with the fixed contacts. Bifurcated contacts are used
in some contactors to avoid bouncing.
The input to the contactor coil may be AC or DC (available in various voltage ranges starting from
Figure 29- Conventional Low voltage contactor coil/ Conventional Low voltage contactor coil Solid Steel Core
26
12Vac/ 12Vdc to 690Vac). A small amount of power is drained by the contactor coil during its operation.
Economizer circuits are used to reduce the power consumed by the contactor during its operation.
Contactors with AC coils have shading coils. Otherwise, the contactor may chatter every time the
alternating current crosses zero. Shading coils delay demagnetization of the magnetic core and avoids
chattering. Shading is not required in DC coils as the flux produced is constant.
Figure 30 - Inside working of contactor
27
2.6 Relay
A relay is classified into many types, a standard and generally used relay is made up of electromagnets
which in general used as a switch. Dictionary says that relay means the act of passing something from
one thing to another, the same meaning can be applied to this device because the signal received from
one side of the device controls the switching operation on the other side. So, relay is a switch which
controls (open and close) circuits electromechanically. The main operation of this device is to make or
break contact with the help of a signal without any human involvement in order to switch it ON or OFF.
It is mainly used to control a high-powered circuit using a low power signal. Generally, a DC signal is
used to control circuit which is driven by high voltage like controlling AC home appliances with DC
signals from microcontrollers.
2.6.1 Design of relay
An electromechanical relay is basically designed using few mechanical parts like Electromagnet, a
movable armature, contacts, yoke, and a spring/frame/stand, these parts are showing in the internal
pictures of Relay below. All these are arranged logically to form into a relay.
2.7 Encoder
Figure 31 - Relay
Figure 32 - Encoder
28
An encoder is a sensor of mechanical motion that generates digital signals in response to motion. As an
electro-mechanical device, an encoder is able to provide motion control system users with information
concerning position, velocity and direction. There are two different types of encoders: linear and rotary.
A linear encoder responds to motion along a path, while a rotary encoder responds to rotational motion.
An encoder is generally categorized by the means of its output. An incremental encoder generates a train
of pulses which can be used to determine position and speed. An absolute encoder generates unique bit
configurations to track positions directly.
2.7.1 Linear encoder
linear encoder is a sensor, transducer or reading-head linked to a scale that encodes position. The sensor
reads the scale and converts position into an analog or digital signal that is transformed into a digital
readout. Movement is determined from changes in position with time. Both optical and magnetic linear
encoder types function using this type of method. However, it is their physical properties which make
them different.
2.7.2 Rotary Encoder
A rotary encoder, also called a shaft encoder, is an electro-mechanical device that converts the angular
position or motion of a shaft or axle to analog or digital output signals. There are two main types of
rotary encoder: absolute and incremental
Encoder
Figure 33- Linear encoder
29
2.7.3 Incremental Encoder
Incremental encoder is a glass disk, LED (light emitting diode), and a photo detector. The transparent
disk contains opaque sections which are equally spaced to deflect light while the transparent sections
allow light to be passed through shown in Figure 34 above. An optical encoder utilizes a light emitting
diode which shines light through the transparent portions of the disk. The light that shines through is
received by the photo detector which produces an electrical signal output.
2.7.4 Absolute encoders
Absolute encoders have a unique code for each shaft position. Or in other words, every position of an
absolute encoder is distinctive. The absolute encoder interprets a system of coded tracks to create
position information where no two positions are identical.
Figure 34 - Rotary Encoder
Figure 35- Incremental and Absolute Encoder
30
2.8 Inductive sensor
Inductive proximity sensors are used in many industrial processes, including food & beverage. Inductive
sensors are those that detect metallic objects without coming in direct contact. Instead, they generate and
use a high-frequency oscillating magnetic field.
Inductive sensors use currents induced by magnetic fields to detect nearby metal objects. The inductive
sensor uses a coil (an inductor) to generate a high frequency magnetic field as shown in Figure 37 below.
If there is a metal object near the changing magnetic field, current will flow in the object.
These work by setting up a high frequency field. If a target nears the field will induce eddy currents.
These currents consume power because of resistance, so energy is in the field is lost, and the signal
amplitude decreases. The detector examines filed magnitude to determine when it has decreased enough
to switch.
The sensors can detect objects a few centimeters away from the end. But, the direction to the object can
be arbitrary as shown in Figure 38 below.
Figure 36 - Inductive Sensor
Figure 37- Inductive proximity sensor
31
The magnetic field of the unshielded sensor covers a larger volume around the head of the coil. By
adding a shield (a metal jacket around the sides of the coil) the magnetic field becomes smaller, but also
more directed. Shields will often be available for inductive sensors to improve their directionality and
accuracy
2.9 VFD (Variable Frequency Drive)
AC motor speed is controlled in two ways – either by controlling the voltage or frequency. Frequency
controlling gives better control due to constant flux density than voltage control. This is where the
working of VFDs comes to play. It is a power conversion device which converts the fixed voltage, fixed
frequency of the input power to the variable voltage, variable frequency output to control AC induction
motors.
It consists of power electronic devices (like IGBT, MOSFET), high speed central controlling unit (such
as microprocessor, DSP) and optional sensing devices depending on the application used.
Most of the industrial applications require variable speeds at peak load conditions and constant speeds
at normal operating conditions. Closed loop working of VFDs maintain the speed of motor at constant
level, even in case of input and load disturbances.
The two main features of variable frequency drive are adjustable speeds and soft start/stop capabilities.
These two features make VFD’s a powerful controller to control the AC motors. VFD consists of mainly
four sections; those are rectifier, intermediate DC link, inverter and controlling circuit.
Figure 38 - Shielded and Unshielded sensors
Figure 39- Variable Frequency Drive
32
The first stage of a Variable Frequency AC Drive, or VFD, is the Converter. The converter is comprised
of six diodes, which are similar to check valves used in plumbing systems. They allow current to flow
in only one direction; the direction shown by the arrow in the diode symbol. For example, whenever A-
phase voltage (voltage is similar to pressure in plumbing systems) is more positive than B or C phase
voltages, then that diode will open and allow current to flow. When B-phase becomes more positive than
A-phase, then the B-phase diode will open and the A-phase diode will close. The same is true for the 3
diodes on the negative side of the bus. Thus, we get six current “pulses” as each diode opens and closes.
This is called a “six-pulse VFD”, which is the standard configuration for current Variable Frequency
Drives.
Figure 40- VFD diagram
Figure 41
33
Assume that the drive is operating on a 480V power system. The 480V rating is “rms” or root-mean-
squared. The peaks on a 480V system are 679V. As you can see, the VFD dc bus has a dc voltage with
an AC ripple. The voltage runs between approximately 580V and 680V.
AC ripple on the DC bus by adding a capacitor. A capacitor operates in a similar fashion to a reservoir
or accumulator in a plumbing system. This capacitor absorbs the ac ripple and delivers a smooth dc
voltage. The AC ripple on the DC bus is typically less than 3 Volts. Thus, the voltage on the DC bus
becomes “approximately” 650VDC. The actual voltage will depend on the voltage level of the AC line
feeding the drive, the level of voltage unbalance on the power system, the motor load, the impedance of
the power system, and any reactors or harmonic filters on the drive.
The diode bridge converter that converts AC-to-DC, is sometimes just referred to as a converter. The
converter that converts the dc back to ac is also a converter, but to distinguish it from the diode converter,
it is usually referred to as an “inverter”. It has become common in the industry to refer to any DC-to-AC
converter as an inverter.
Figure 42 - Rectifier output wave
34
When we close one of the top switches in the inverter, that phase of the motor is connected to the positive
dc bus and the voltage on that phase becomes positive. When we close one of the bottom switches in the
converter, that phase is connected to the negative dc bus and becomes negative. Thus, we can make any
phase on the motor become positive or negative at will and can thus generate any frequency that we
want. So, we can make any phase be positive, negative, or zero.
Figure 43- Real VFD, the switches shown would actually be transistors.
Figure 44- The blue sine-wave is shown for comparison purposes
35
The output from the VFD is a “rectangular” wave form. VFD’s do not produce a sinusoidal output. This
rectangular waveform would not be a good choice for a general purpose distribution system, but is
perfectly adequate for a motor.
If we want to reduce the motor frequency to 30 Hz, then we simply switch the inverter output transistors
more slowly. But, if we reduce the frequency to 30Hz, then we must also reduce the voltage to 240V in
order to maintain the V/Hz ratio (see the VFD Motor Theory presentation for more on this). How are we
going to reduce the voltage if the only voltage we have is 650VDC?
This is called Pulse Width Modulation or PWM. Imagine that we could control the pressure in a water
line by turning the valve on and off at a high rate of speed. While this would not be practical for plumbing
systems, it works very well for VFD’s. Notice that during the first half cycle, the voltage is ON half the
time and OFF half the time. Thus, the average voltage is half of 480V or 240V. By pulsing the output,
we can achieve any average voltage on the output of the VFD.
2.9.1 Advantage of VFD
• Reduce Energy Consumption and Energy Costs
• increase Production Through Tighter Process Control.
• Extend Equipment Life and Reduce Maintenance.
2.9.2 Application of VFD
• Safe Acceleration.
• Emergency bypass capability
• Energy saving on most pump and fan application.
• Better process control and regulation.
• Speeding up or slowing down a machine or process
36
2.10 Metal detector
In CBL International Plant every full finished product finally will go through metal detector. Its mean
there are so many metal detectors. Food Industry. Metal Detectors detect metal contaminants
accidentally present on industrial products, with levels of sensitivity, immunity to interference and
response speeds designed to satisfy the strictest Quality Control requirements. Metal Detectors sense
and remove the presence of ferrous, non-ferrous and stainless metals in the process flow in-line, in free-
fall applications, and in conjunction with conveyors. These units also find metal encapsulated in the
individual particle. Successful detection and separation of metal will protect that processing equipment
from damage, which saves your organization money and down time.
The operation of metal detectors is based upon the principles of electromagnetic induction. Metal
detectors contain one or more inductor coils that are used to interact with metallic elements on the
ground. The single-coil detector illustrated below is a simplified version of one used in a real metal
detector.
Figure 45- Metal Detector
Figure 47- Induces a magnetic field Figure 46- Eddy currents induce their own magnetic field
37
A pulsing current is applied to the coil, which then induces a magnetic field shown in blue. When the
magnetic field of the coil moves across metal, such as the coin in this illustration, the field induces
electric currents (called eddy currents) in the coin. The eddy currents induce their own magnetic field,
shown in red, which generates an opposite current in the coil, which induces a signal indicating the
presence of metal.
2.11 Programmable Logic Controller (PLC)
Programmable Logic Controller (PLC) is a special computer device used in industrial control systems.
Due to its robust construction, exceptional functional features like sequential control, counters and
timers, ease of programming, reliable controlling capabilities and ease of hardware usage – this PLC is
used as more than a special-purpose digital computer in industries as well as in other control-system
areas. Most of the industries abbreviate these devices as “PC” but it is also used for personal computers;
due to this, many manufacturers named these devices as PLCs.
The programmable logic controller is used not only for industrial purpose but also in civil applications
such as washing machine, elevators working and traffic signals control. Different types of PLCs from a
vast number of manufacturers are available in today’s market. Therefore, in the following paragraphs,
let us study about programmable logic controller’s basics, principles and applications.
Programmable Logic Controllers are used for continuously monitoring the input values from sensors
and produces the outputs for the operation of actuators based on the program. Every PLC system
comprises these three modules:
• CPU module
• Power supply module
• One or more I/O module
Figure 48- Programmable Logic Controller (PLC)
38
2.11.1 PLC Architecture
2.11.2 CPU Module:
A CPU module consists of central processor and its memory. The processor is responsible for performing
all the necessary computations and processing of data by accepting the inputs and producing the
appropriate outputs.
2.11.3 Power Supply Module:
This module supplies the required power to the whole system by converting the available AC power to
DC power required for the CPU and I/O modules. The 5V DC output drives the computer circuitry.
2.11.4 I/O Modules:
The input and out modules of the programmable logic controller are used to connect the sensors and
actuators to the system to sense the various parameters such as temperature, pressure and flow, etc. These
I/O modules are of two types: digital or analog.
2.11.5 Communication Interface Modules:
These are intelligent I/O modules which transfers the information between a CPU and communication
network. These communication modules are used for communicating with other PLC’s and computers,
which are placed at remote place or far-off locate.
Figure 49- PLC Architecture
39
The program in the CPU of programmable logic controller consists of operating system and user
programs. The purpose of the operating system with CPU is to deal with the tasks and operations of the
PLC such as starting and stopping operations, storage area and communication management, etc. A user
program is used by the user for finishing and controlling the tasks in automation. The Principle of
operation of the PLC can be understood with the cyclic scanning also called as scan cycle, which is given
in the below figure 50
Typical PLC scans cycle includes of the following steps:
• The operating system starts cycling and monitoring of time.
• The CPU starts reading the data from the input module and checks the status of all the inputs.
• The CPU starts executing the user or application program written in relay-ladder logic or any
other PLC-programming language.
• Next, the CPU performs all the internal diagnosis and communication tasks.
• According to the program results, it writes the data into the output module so that all outputs are
updated.
• This process continues as long as the PLC is in run mode.
Figure 50- PLC Scan Cycle
40
2.11.6 Application of PLC automation system
As one of the most technology enabled FMCG companies in Sri Lanka, CBL manufactures varied food
products in state-of-the art facilities. By using PLC automation in a fully automated continuous
manufacturing process with a class 100,000 clean room, cakes are devoid of human contact during
production. They have a modern plant & equipment for the automation of the complete production
process of soy-based foods. Production includes American machinery and is a fully automated
continuous manufacturing process within a highly controlled environment.
41
3 CONCLUSION TO THE REPORT
The industrial training is a compulsory part of our diploma program, which is offered by University
College of Ratmalana This is a very valuable opportunity for all the students who are following the
diploma program. It is offered by University College of Ratmalana with NAITA.our practical knowledge
on industrial techniques and procedures were poor. Though we gained a good theoretical knowledge on
various subject areas, our practical knowledge is not at an appreciative level. It is better when we are
familiar with how the theories we learn would be applied in the industry. It is a remarkable point of the
Diploma program, to gain 6 months’ experience in the industry. Opportunity, we gained to absorb the
knowledge from experts in various subject areas was extremely valuable. Also, the ability to face
interviews and social skills acquire a great improvement due to this opportunity.
It should be mentioned that the knowledge gained during the course of the training was not strictly
restricted to my chosen disciple. This I see as one of the best things about the training since it allowed
us to explore and familiarize ourselves with numerous practical aspects found in a real industrial site.
To elaborate, some examples would be the knowledge of organizational arrangement and hierarchy that
was gained through the training. This knowledge would be found indispensable on a future date when
working as a professional.
As conclusion I would like to summarize the jobs, I have done at CBL Foods International (Pvt) Ltd. As
major projects I can mention the Electrical and Electronics Equipment Repairing and Servicing Record,
General Electrical Audit report, Compressed Air Energy Conservation project through that project I
could calculate and identified what are compressed air wasting condition how much Electricity waste
for it.
For that I had to visit every corner of the plant and observe the current company Compressed air system
and what are areas compressed air wasting. I learnt a lot from these projects. Apart from the vast amount
of technical knowledge which we could gain from the training, it did another great service in allowing
us to learn how to conduct ourselves in a professional manner which would be found a particularly useful
skill in the future. This was the first instance where we were expected to display true professional
behavior and we were given responsibilities to handle. In my opinion, the development of this aspect of
our personalities was just as useful as the development of technical knowledge. Thus, the industrial
training may be justly described as a most necessary process in the path to become a professional.
42
4 REFERENCE
• [1] [1] LMD. (2018). CEYLON BISCUITS LIMITED LMD. [online] Available at
https://lmd.lk/ceylon-biscuits-limited-3/ [Accessed 01 August 2019].
• [2] Daily Dairy of the NITA
• [3] Refer the NITA record book.
• [4] (2008), IET wiring Regulation, Requirements for Electrical installations, UK
• [5] Theraja, B.L, (2005), A text book of Electrical technology, S. Chand & company LTD, Ram
nagar,New Delhi, India
43
CERTIFICATION
Name of the trainee : - B.A.D.Idumal
ID No : -
Address : -
Institute & Address : - University Collage of Rathmalana
Programme : - Electrical Technology (NVQ5, NVQ6)
Training Organization and Address : - CBL Foods International (pvt) Ltd
Habarakada road, Ranala,
Training period : - 01.08.2019 to 07.08.2019
This is to certify that this report is prepared by myself under the training conduct at above organization.
……………………… ……………………….
Date Signature of the trainee
This is to certify that this report is prepared by above trainee under my regular supervision.
……………………… ……………………….
44
Date Signature of the Employer with stamp

More Related Content

What's hot (20)

Training Report
Training ReportTraining Report
Training Report
 
Ceylon Electricity Board
Ceylon Electricity BoardCeylon Electricity Board
Ceylon Electricity Board
 
Training report
Training reportTraining report
Training report
 
Industrial Training Report-II-DIMO
Industrial Training Report-II-DIMOIndustrial Training Report-II-DIMO
Industrial Training Report-II-DIMO
 
Start (ceb) new
Start (ceb) newStart (ceb) new
Start (ceb) new
 
Internship report 2007eit043
Internship report 2007eit043Internship report 2007eit043
Internship report 2007eit043
 
Training report_orginal
Training report_orginalTraining report_orginal
Training report_orginal
 
Training Report CEB
Training Report CEBTraining Report CEB
Training Report CEB
 
Training Report WSO2 internship
Training Report  WSO2 internshipTraining Report  WSO2 internship
Training Report WSO2 internship
 
Frist
Frist Frist
Frist
 
Final training report PDF
Final training report PDFFinal training report PDF
Final training report PDF
 
Internship report
Internship reportInternship report
Internship report
 
NATPET Report
NATPET ReportNATPET Report
NATPET Report
 
Industrial Training Report - SLT
Industrial Training Report - SLTIndustrial Training Report - SLT
Industrial Training Report - SLT
 
Internship Report
Internship Report Internship Report
Internship Report
 
Colombo Dockyard PLC Industrial Training Report
Colombo Dockyard PLC Industrial Training ReportColombo Dockyard PLC Industrial Training Report
Colombo Dockyard PLC Industrial Training Report
 
Internship Wso2
Internship Wso2Internship Wso2
Internship Wso2
 
Training presentation at CGR
Training presentation at CGRTraining presentation at CGR
Training presentation at CGR
 
Bhel summer training (industrial training) report
Bhel summer training (industrial training) reportBhel summer training (industrial training) report
Bhel summer training (industrial training) report
 
In-Plant Training Report
In-Plant Training ReportIn-Plant Training Report
In-Plant Training Report
 

Similar to National Apprentice & Industrial Training Authority Report on Industrial Training At CBL FOODS INTERNATIONAL (PVT) LTD HABARAKADA ROAD, RANALA,

An OJT Report On 3 Month Internship at Surya Nepal
An OJT Report On 3 Month Internship at Surya NepalAn OJT Report On 3 Month Internship at Surya Nepal
An OJT Report On 3 Month Internship at Surya NepalBikram Dahal
 
HMT Machine Tools Ltd Ajmer Practical Summer Training Report
HMT Machine Tools Ltd Ajmer Practical Summer Training ReportHMT Machine Tools Ltd Ajmer Practical Summer Training Report
HMT Machine Tools Ltd Ajmer Practical Summer Training ReportSiddharth Bhatnagar
 
INTERNSHIP REPORT (Repaired).docx
INTERNSHIP REPORT (Repaired).docxINTERNSHIP REPORT (Repaired).docx
INTERNSHIP REPORT (Repaired).docxPaulosMekuria
 
Report of activities of trade creditors section of the acme laboratories ltd
Report of activities of trade creditors section of the acme laboratories ltdReport of activities of trade creditors section of the acme laboratories ltd
Report of activities of trade creditors section of the acme laboratories ltdMd Parvez Khan
 
Satellite Systems and Terrestrial TV Distribution and receiving systems
Satellite Systems and Terrestrial TV Distribution and receiving systems Satellite Systems and Terrestrial TV Distribution and receiving systems
Satellite Systems and Terrestrial TV Distribution and receiving systems Chamira Nanayakkara
 
Ashirbad Paints - Marketing Department - Vishal Koirala.pdf
Ashirbad Paints - Marketing Department - Vishal Koirala.pdfAshirbad Paints - Marketing Department - Vishal Koirala.pdf
Ashirbad Paints - Marketing Department - Vishal Koirala.pdfAakashKhanal3
 
Sri Lanka Lorts Authority
Sri Lanka Lorts AuthoritySri Lanka Lorts Authority
Sri Lanka Lorts AuthorityRifDhy RM
 
PTCL Internship Report (Awais Rahimoon)
PTCL Internship Report (Awais Rahimoon)PTCL Internship Report (Awais Rahimoon)
PTCL Internship Report (Awais Rahimoon)Awais Rahimoon
 
Industrial Training Report on PLC & SCADA
Industrial Training Report on PLC & SCADAIndustrial Training Report on PLC & SCADA
Industrial Training Report on PLC & SCADAAman Jaiswal
 
Final report
Final reportFinal report
Final reportAMSADO
 
Industrial Training Report, UmaOya Downstream Development Project
Industrial Training Report, UmaOya Downstream Development ProjectIndustrial Training Report, UmaOya Downstream Development Project
Industrial Training Report, UmaOya Downstream Development ProjectMohamed Juzaafi
 
Mumias Sugar Report
Mumias Sugar ReportMumias Sugar Report
Mumias Sugar ReportObara Daddie
 
Report on Steamt Turbines, BHEL HYDERABAD.
Report on Steamt Turbines, BHEL HYDERABAD.Report on Steamt Turbines, BHEL HYDERABAD.
Report on Steamt Turbines, BHEL HYDERABAD.Viswanath Raju Indukuri
 
Internship Report on R.k. group
Internship Report on R.k. groupInternship Report on R.k. group
Internship Report on R.k. groupMasum Billah
 

Similar to National Apprentice & Industrial Training Authority Report on Industrial Training At CBL FOODS INTERNATIONAL (PVT) LTD HABARAKADA ROAD, RANALA, (20)

1st Report at Nikini Automation1
1st Report at Nikini Automation11st Report at Nikini Automation1
1st Report at Nikini Automation1
 
An OJT Report On 3 Month Internship at Surya Nepal
An OJT Report On 3 Month Internship at Surya NepalAn OJT Report On 3 Month Internship at Surya Nepal
An OJT Report On 3 Month Internship at Surya Nepal
 
HMT Machine Tools Ltd Ajmer Practical Summer Training Report
HMT Machine Tools Ltd Ajmer Practical Summer Training ReportHMT Machine Tools Ltd Ajmer Practical Summer Training Report
HMT Machine Tools Ltd Ajmer Practical Summer Training Report
 
Kandil_Sameh_AR50411_Part 1 to 5
Kandil_Sameh_AR50411_Part 1 to 5Kandil_Sameh_AR50411_Part 1 to 5
Kandil_Sameh_AR50411_Part 1 to 5
 
INTERNSHIP REPORT (Repaired).docx
INTERNSHIP REPORT (Repaired).docxINTERNSHIP REPORT (Repaired).docx
INTERNSHIP REPORT (Repaired).docx
 
Report of activities of trade creditors section of the acme laboratories ltd
Report of activities of trade creditors section of the acme laboratories ltdReport of activities of trade creditors section of the acme laboratories ltd
Report of activities of trade creditors section of the acme laboratories ltd
 
Satellite Systems and Terrestrial TV Distribution and receiving systems
Satellite Systems and Terrestrial TV Distribution and receiving systems Satellite Systems and Terrestrial TV Distribution and receiving systems
Satellite Systems and Terrestrial TV Distribution and receiving systems
 
Ashirbad Paints - Marketing Department - Vishal Koirala.pdf
Ashirbad Paints - Marketing Department - Vishal Koirala.pdfAshirbad Paints - Marketing Department - Vishal Koirala.pdf
Ashirbad Paints - Marketing Department - Vishal Koirala.pdf
 
Training report
Training reportTraining report
Training report
 
Sri Lanka Lorts Authority
Sri Lanka Lorts AuthoritySri Lanka Lorts Authority
Sri Lanka Lorts Authority
 
PTCL Internship Report (Awais Rahimoon)
PTCL Internship Report (Awais Rahimoon)PTCL Internship Report (Awais Rahimoon)
PTCL Internship Report (Awais Rahimoon)
 
Industrial Training Report on PLC & SCADA
Industrial Training Report on PLC & SCADAIndustrial Training Report on PLC & SCADA
Industrial Training Report on PLC & SCADA
 
REPORT ON HMT
REPORT ON HMTREPORT ON HMT
REPORT ON HMT
 
Final report
Final reportFinal report
Final report
 
Industrial Training Report, UmaOya Downstream Development Project
Industrial Training Report, UmaOya Downstream Development ProjectIndustrial Training Report, UmaOya Downstream Development Project
Industrial Training Report, UmaOya Downstream Development Project
 
latihan industri
latihan industrilatihan industri
latihan industri
 
Customer satisfaction level of prepaid subscribers of airtel bangladesh limit...
Customer satisfaction level of prepaid subscribers of airtel bangladesh limit...Customer satisfaction level of prepaid subscribers of airtel bangladesh limit...
Customer satisfaction level of prepaid subscribers of airtel bangladesh limit...
 
Mumias Sugar Report
Mumias Sugar ReportMumias Sugar Report
Mumias Sugar Report
 
Report on Steamt Turbines, BHEL HYDERABAD.
Report on Steamt Turbines, BHEL HYDERABAD.Report on Steamt Turbines, BHEL HYDERABAD.
Report on Steamt Turbines, BHEL HYDERABAD.
 
Internship Report on R.k. group
Internship Report on R.k. groupInternship Report on R.k. group
Internship Report on R.k. group
 

Recently uploaded

Sanyam Choudhary Chemistry practical.pdf
Sanyam Choudhary Chemistry practical.pdfSanyam Choudhary Chemistry practical.pdf
Sanyam Choudhary Chemistry practical.pdfsanyamsingh5019
 
Final demo Grade 9 for demo Plan dessert.pptx
Final demo Grade 9 for demo Plan dessert.pptxFinal demo Grade 9 for demo Plan dessert.pptx
Final demo Grade 9 for demo Plan dessert.pptxAvyJaneVismanos
 
A Critique of the Proposed National Education Policy Reform
A Critique of the Proposed National Education Policy ReformA Critique of the Proposed National Education Policy Reform
A Critique of the Proposed National Education Policy ReformChameera Dedduwage
 
Alper Gobel In Media Res Media Component
Alper Gobel In Media Res Media ComponentAlper Gobel In Media Res Media Component
Alper Gobel In Media Res Media ComponentInMediaRes1
 
Employee wellbeing at the workplace.pptx
Employee wellbeing at the workplace.pptxEmployee wellbeing at the workplace.pptx
Employee wellbeing at the workplace.pptxNirmalaLoungPoorunde1
 
Science 7 - LAND and SEA BREEZE and its Characteristics
Science 7 - LAND and SEA BREEZE and its CharacteristicsScience 7 - LAND and SEA BREEZE and its Characteristics
Science 7 - LAND and SEA BREEZE and its CharacteristicsKarinaGenton
 
ENGLISH5 QUARTER4 MODULE1 WEEK1-3 How Visual and Multimedia Elements.pptx
ENGLISH5 QUARTER4 MODULE1 WEEK1-3 How Visual and Multimedia Elements.pptxENGLISH5 QUARTER4 MODULE1 WEEK1-3 How Visual and Multimedia Elements.pptx
ENGLISH5 QUARTER4 MODULE1 WEEK1-3 How Visual and Multimedia Elements.pptxAnaBeatriceAblay2
 
Introduction to ArtificiaI Intelligence in Higher Education
Introduction to ArtificiaI Intelligence in Higher EducationIntroduction to ArtificiaI Intelligence in Higher Education
Introduction to ArtificiaI Intelligence in Higher Educationpboyjonauth
 
POINT- BIOCHEMISTRY SEM 2 ENZYMES UNIT 5.pptx
POINT- BIOCHEMISTRY SEM 2 ENZYMES UNIT 5.pptxPOINT- BIOCHEMISTRY SEM 2 ENZYMES UNIT 5.pptx
POINT- BIOCHEMISTRY SEM 2 ENZYMES UNIT 5.pptxSayali Powar
 
The Most Excellent Way | 1 Corinthians 13
The Most Excellent Way | 1 Corinthians 13The Most Excellent Way | 1 Corinthians 13
The Most Excellent Way | 1 Corinthians 13Steve Thomason
 
_Math 4-Q4 Week 5.pptx Steps in Collecting Data
_Math 4-Q4 Week 5.pptx Steps in Collecting Data_Math 4-Q4 Week 5.pptx Steps in Collecting Data
_Math 4-Q4 Week 5.pptx Steps in Collecting DataJhengPantaleon
 
18-04-UA_REPORT_MEDIALITERAСY_INDEX-DM_23-1-final-eng.pdf
18-04-UA_REPORT_MEDIALITERAСY_INDEX-DM_23-1-final-eng.pdf18-04-UA_REPORT_MEDIALITERAСY_INDEX-DM_23-1-final-eng.pdf
18-04-UA_REPORT_MEDIALITERAСY_INDEX-DM_23-1-final-eng.pdfssuser54595a
 
Incoming and Outgoing Shipments in 1 STEP Using Odoo 17
Incoming and Outgoing Shipments in 1 STEP Using Odoo 17Incoming and Outgoing Shipments in 1 STEP Using Odoo 17
Incoming and Outgoing Shipments in 1 STEP Using Odoo 17Celine George
 
BASLIQ CURRENT LOOKBOOK LOOKBOOK(1) (1).pdf
BASLIQ CURRENT LOOKBOOK  LOOKBOOK(1) (1).pdfBASLIQ CURRENT LOOKBOOK  LOOKBOOK(1) (1).pdf
BASLIQ CURRENT LOOKBOOK LOOKBOOK(1) (1).pdfSoniaTolstoy
 
Solving Puzzles Benefits Everyone (English).pptx
Solving Puzzles Benefits Everyone (English).pptxSolving Puzzles Benefits Everyone (English).pptx
Solving Puzzles Benefits Everyone (English).pptxOH TEIK BIN
 
How to Configure Email Server in Odoo 17
How to Configure Email Server in Odoo 17How to Configure Email Server in Odoo 17
How to Configure Email Server in Odoo 17Celine George
 
Software Engineering Methodologies (overview)
Software Engineering Methodologies (overview)Software Engineering Methodologies (overview)
Software Engineering Methodologies (overview)eniolaolutunde
 

Recently uploaded (20)

Sanyam Choudhary Chemistry practical.pdf
Sanyam Choudhary Chemistry practical.pdfSanyam Choudhary Chemistry practical.pdf
Sanyam Choudhary Chemistry practical.pdf
 
Final demo Grade 9 for demo Plan dessert.pptx
Final demo Grade 9 for demo Plan dessert.pptxFinal demo Grade 9 for demo Plan dessert.pptx
Final demo Grade 9 for demo Plan dessert.pptx
 
A Critique of the Proposed National Education Policy Reform
A Critique of the Proposed National Education Policy ReformA Critique of the Proposed National Education Policy Reform
A Critique of the Proposed National Education Policy Reform
 
Alper Gobel In Media Res Media Component
Alper Gobel In Media Res Media ComponentAlper Gobel In Media Res Media Component
Alper Gobel In Media Res Media Component
 
Employee wellbeing at the workplace.pptx
Employee wellbeing at the workplace.pptxEmployee wellbeing at the workplace.pptx
Employee wellbeing at the workplace.pptx
 
Science 7 - LAND and SEA BREEZE and its Characteristics
Science 7 - LAND and SEA BREEZE and its CharacteristicsScience 7 - LAND and SEA BREEZE and its Characteristics
Science 7 - LAND and SEA BREEZE and its Characteristics
 
ENGLISH5 QUARTER4 MODULE1 WEEK1-3 How Visual and Multimedia Elements.pptx
ENGLISH5 QUARTER4 MODULE1 WEEK1-3 How Visual and Multimedia Elements.pptxENGLISH5 QUARTER4 MODULE1 WEEK1-3 How Visual and Multimedia Elements.pptx
ENGLISH5 QUARTER4 MODULE1 WEEK1-3 How Visual and Multimedia Elements.pptx
 
Introduction to ArtificiaI Intelligence in Higher Education
Introduction to ArtificiaI Intelligence in Higher EducationIntroduction to ArtificiaI Intelligence in Higher Education
Introduction to ArtificiaI Intelligence in Higher Education
 
POINT- BIOCHEMISTRY SEM 2 ENZYMES UNIT 5.pptx
POINT- BIOCHEMISTRY SEM 2 ENZYMES UNIT 5.pptxPOINT- BIOCHEMISTRY SEM 2 ENZYMES UNIT 5.pptx
POINT- BIOCHEMISTRY SEM 2 ENZYMES UNIT 5.pptx
 
The Most Excellent Way | 1 Corinthians 13
The Most Excellent Way | 1 Corinthians 13The Most Excellent Way | 1 Corinthians 13
The Most Excellent Way | 1 Corinthians 13
 
_Math 4-Q4 Week 5.pptx Steps in Collecting Data
_Math 4-Q4 Week 5.pptx Steps in Collecting Data_Math 4-Q4 Week 5.pptx Steps in Collecting Data
_Math 4-Q4 Week 5.pptx Steps in Collecting Data
 
18-04-UA_REPORT_MEDIALITERAСY_INDEX-DM_23-1-final-eng.pdf
18-04-UA_REPORT_MEDIALITERAСY_INDEX-DM_23-1-final-eng.pdf18-04-UA_REPORT_MEDIALITERAСY_INDEX-DM_23-1-final-eng.pdf
18-04-UA_REPORT_MEDIALITERAСY_INDEX-DM_23-1-final-eng.pdf
 
Staff of Color (SOC) Retention Efforts DDSD
Staff of Color (SOC) Retention Efforts DDSDStaff of Color (SOC) Retention Efforts DDSD
Staff of Color (SOC) Retention Efforts DDSD
 
Incoming and Outgoing Shipments in 1 STEP Using Odoo 17
Incoming and Outgoing Shipments in 1 STEP Using Odoo 17Incoming and Outgoing Shipments in 1 STEP Using Odoo 17
Incoming and Outgoing Shipments in 1 STEP Using Odoo 17
 
BASLIQ CURRENT LOOKBOOK LOOKBOOK(1) (1).pdf
BASLIQ CURRENT LOOKBOOK  LOOKBOOK(1) (1).pdfBASLIQ CURRENT LOOKBOOK  LOOKBOOK(1) (1).pdf
BASLIQ CURRENT LOOKBOOK LOOKBOOK(1) (1).pdf
 
Solving Puzzles Benefits Everyone (English).pptx
Solving Puzzles Benefits Everyone (English).pptxSolving Puzzles Benefits Everyone (English).pptx
Solving Puzzles Benefits Everyone (English).pptx
 
How to Configure Email Server in Odoo 17
How to Configure Email Server in Odoo 17How to Configure Email Server in Odoo 17
How to Configure Email Server in Odoo 17
 
9953330565 Low Rate Call Girls In Rohini Delhi NCR
9953330565 Low Rate Call Girls In Rohini  Delhi NCR9953330565 Low Rate Call Girls In Rohini  Delhi NCR
9953330565 Low Rate Call Girls In Rohini Delhi NCR
 
TataKelola dan KamSiber Kecerdasan Buatan v022.pdf
TataKelola dan KamSiber Kecerdasan Buatan v022.pdfTataKelola dan KamSiber Kecerdasan Buatan v022.pdf
TataKelola dan KamSiber Kecerdasan Buatan v022.pdf
 
Software Engineering Methodologies (overview)
Software Engineering Methodologies (overview)Software Engineering Methodologies (overview)
Software Engineering Methodologies (overview)
 

National Apprentice & Industrial Training Authority Report on Industrial Training At CBL FOODS INTERNATIONAL (PVT) LTD HABARAKADA ROAD, RANALA,

  • 1. i National Apprentice & Industrial Training Authority Report on Industrial Training At CBL FOODS INTERNATIONAL (PVT) LTD HABARAKADA ROAD, RANALA, University Collage of Rathmalana Rathmalana Name : B.A.D.Idumal Student Number : RT/ECT/17/0003 Course : Higher National Diploma in Electrical Technology Field : Electrical Period : 06 months
  • 2. i ACKNOWLEDGMENT First of all, I would like to offer my sincere gratitude to the Industrial Training Division of University collage of Rathmalana, National Apprentice and Training Authority (NAITA) and also CBL Foods International (Pvt) Ltd for giving me this opportunity to enhance my technical knowledge. I would like to thank Our Lecture and student coordinator Mr. Prabhath Sanjeewa Herath and all the staff members of Industrial Training Division of University collage of Rathmalana & Industrial Training Authority (NAITA). organizing such a valuable industrial training program for us. Without them I won't be able to get such a valuable training experience. Then I would like to convey my gratitude to Further, I would especially like to thank to the training manager of CBLF and the HR Executive of CBLF for giving the training opportunity and introduction to the factory environment. Also, I would like to thank head of electrical engineers and other all Engineers, Supervisors and Technicians for their great support. Last, I want to offer my gratitude to all others who may have forgotten to mention above for their great support to me. I sincerely thank all colleagues who assisted me in every possible way to make industrial training a success. B.A.D.Idumal Higher National Diploma, Department of Electrical Technology, University Collage of Rathmalana.
  • 3. ii PREFACE In this report, the experience and knowledge that I have gained during my first industrial training program has been included. The way faced and handled the encountered problems and the solutions given to them have been included in this report. The first industrial training was at CBL FOODS INTERNATIONAL (PVT) LTD, Ranala from 08th January to 7th July 2019. During these 6 month of training period, I was able to interact with real engineering experience and also it helped to acquire additional theoretical knowledge about industrial applications. In this report, there are mentioned all the knowledge and working experience that have been obtained during this limited time period. This report is consisted of mainly 3 major chapters. First chapter mainly includes Information about Training Establishment. Then First chapter describes main functions, Organizational chart, Nature of business and Vision, Mission, Management style, Present Performance and safety practices. The second chapter mainly describes training experience at the Training Establishment, it contains about the technical experience and provides the information about the projects I have done during the training period, in Head office, workshop and plants area. The third or final chapter includes the conclusion of the report. This conclusion includes an assessment on the current Industrial Program.
  • 4. iii Table of Content 1 INTRODUCTION TO THE TRAINING ESTABLISHMENT..........................1 1.1 HISTORY OF THE CEYLON BISCUIT LIMITED........................................................................... 1 1.1.1 Nature of Business .......................................................................................................... 1 1.1.2 Departments of The Company.......................................................................................... 3 1.1.3 Production Plants of the Company.................................................................................... 3 1.1.4 Organizational chart ......................................................................................................... 4 1.2 CO – OPERATE PLAN.............................................................................................................. 5 1.2.1 Vision .............................................................................................................................. 5 1.2.2 Mission ............................................................................................................................ 5 1.3 MANAGEMENT PRACTICES .................................................................................................... 5 1.3.1 Recruitment Procedure..................................................................................................... 7 1.4 PERSONAL PROTECTIVE EQUIPMENT (PPE)............................................................................ 9 1.4.1 Safety Equipment............................................................................................................. 9 1.4.2 Electricalsafetysymbols.................................................................................................... 11 1.4.3 Electrical Safety clothing................................................................................................ 12 2 TRAINING EXPERIENCE................................................................................13 2.1 AC POWER DISTRIBUTION................................................................................................... 14 2.1.1 Single phase wire system................................................................................................ 14 2.1.2 Three phase wire system ................................................................................................ 14 2.1.3 Type of wire with their current carried capacity.............................................................. 15 2.1.4 Cable Wire Protection .................................................................................................... 15 2.1.5 DDLO (Drop Down Lift On).......................................................................................... 16 2.2 WHAT IS EARTH FAULT....................................................................................................... 18 2.2.1 How Earth Fault Protection Devices working ................................................................. 18 2.2.2 Earth Fault Relay (EFR)................................................................................................. 18 2.2.3 Earth Leakage Circuit Breaker........................................................................................ 18 2.2.4 Ground Fault Circuit Interrupter..................................................................................... 19 2.2.5 Restricted Earth Fault Protection Scheme ....................................................................... 19 2.2.6 Short Circuit Protection Devices..................................................................................... 20 2.2.7 Fuse ............................................................................................................................... 20 2.2.8 Circuit Breaker............................................................................................................... 20 2.3 A MOLDED CASE CIRCUIT BREAKER (MCCB)..................................................................... 21 2.3.1 The Operates of MCCB.................................................................................................. 21
  • 5. iv 2.4 MOTOR PROTECTION CIRCUIT BREAKER (MPCB)................................................................ 22 2.5 CONTACTOR ....................................................................................................................... 24 2.5.1 Inside of Contactor Coil ................................................................................................. 25 2.6 RELAY................................................................................................................................ 27 2.6.1 Design of relay............................................................................................................... 27 2.7 ENCODER............................................................................................................................ 27 2.7.1 Linear encoder ............................................................................................................... 28 2.7.2 Rotary Encoder .............................................................................................................. 28 2.7.3 Incremental Encoder ...................................................................................................... 29 2.7.4 Absolute encoders .......................................................................................................... 29 2.8 INDUCTIVE SENSOR ............................................................................................................. 30 2.9 VFD (VARIABLE FREQUENCY DRIVE) ................................................................................. 31 2.9.1 Advantage of VFD ......................................................................................................... 35 2.9.2 Application of VFD........................................................................................................ 35 2.10 METAL DETECTOR............................................................................................................... 36 2.11 PROGRAMMABLE LOGIC CONTROLLER (PLC)...................................................................... 37 2.11.1 PLC Architecture........................................................................................................ 38 2.11.2 CPU Module: ............................................................................................................. 38 2.11.3 Power Supply Module: ............................................................................................... 38 2.11.4 I/O Modules: .............................................................................................................. 38 2.11.5 Communication Interface Modules:............................................................................ 38 2.11.6 Application of PLC automation system....................................................................... 40 3 CONCLUSION TO THE REPORT...................................................................41 4 REFERENCE ......................................................................................................42 List of Table TABLE 1 - SAFETY SYMBOLS............................................................................................................... 11 TABL2 - CURRENT CARRIED CAPACITY............................................................................................... 15
  • 6. v Table of Figure FIGURE 1 - CEYLON BISCUIT LIMITED (1968)........................................................................................ 1 FIGURE 2 - CBL GROUP OF COMPANIES ................................................................................................ 1 FIGURE 3 - CBL FOODS INTERNATIONAL (PVT) LTD............................................................................. 2 FIGURE 4 - CBL LOGO.......................................................................................................................... 2 FIGURE 5 - LOCATION OF THE COMPANY............................................................................................... 2 FIGURE 6 - MANAGEMENT HIERARCHY OF THE ENGINEERING DEPARTMENT .......................................... 3 FIGURE 7 - ORGANIZATIONAL CHART.................................................................................................... 4 FIGURE 8 - COOPERATE VISION AND MISSION ....................................................................................... 5 FIGURE 9 - SAFETY HELMET ................................................................................................................. 9 FIGURE 10 - SAFETY GOOGLES.............................................................................................................. 9 FIGURE 11 - SAFETY SHOES .................................................................................................................. 9 FIGURE 12 - EAR MUFFS..................................................................................................................... 10 FIGURE 13 - ELECTRICAL GLOVES....................................................................................................... 10 FIGURE 14 - SAFETY CLOTHING........................................................................................................... 12 FIGURE 15 - WIRING SYSTEM TYPES ................................................................................................... 14 FIGURE 16 - OLD WIRE AND NEW COLOR CODE ................................................................................... 14 FIGURE 17- OLD WIRE AND NEW COLOR CODE.................................................................................... 15 FIGURE 18 - CABLE WIRE INSULATION................................................................................................ 15 FIGURE 19 - DDLO (DROP DOWN LIFE ON)........................................................................................ 16 FIGURE 20 - FUSE LINK....................................................................................................................... 17 FIGURE 21 - FUSE LINK....................................................................................................................... 17 FIGURE 22 - EARTH FAULT RELAY...................................................................................................... 18 FIGURE 23- EARTH FAULT PROTECTION WITH ..................................................................................... 19 FIGURE 24 - FUSE ............................................................................................................................... 20 FIGURE 25 - MOLDED CASE CIRCUIT BREAKER (MCCB)..................................................................... 21 FIGURE 26 - MPCB ............................................................................................................................ 22 FIGURE 27 - CONTACTOR.................................................................................................................... 24 FIGURE 28- CONVENTIONAL LAMINATED SOFT IRON MAGNETIC CORE................................................. 24 FIGURE 29- CONVENTIONAL LOW VOLTAGE CONTACTOR COIL/ CONVENTIONAL LOW VOLTAGE CONTACTOR COIL SOLID STEEL CORE.......................................................................................... 25 FIGURE 30 - INSIDE WORKING OF CONTACTOR ..................................................................................... 26 FIGURE 31 - RELAY ............................................................................................................................ 27 FIGURE 32 - ENCODER ........................................................................................................................ 27 FIGURE 33- LINEAR ENCODER............................................................................................................. 28 FIGURE 34 - ROTARY ENCODER .......................................................................................................... 29
  • 7. vi FIGURE 35- INCREMENTAL AND ABSOLUTE ENCODER ......................................................................... 29 FIGURE 36 - INDUCTIVE SENSOR ......................................................................................................... 30 FIGURE 37- INDUCTIVE PROXIMITY SENSOR......................................................................................... 30 FIGURE 38 - SHIELDED AND UNSHIELDED SENSORS.............................................................................. 31 FIGURE 39- VARIABLE FREQUENCY DRIVE.......................................................................................... 31 FIGURE 40- VFD DIAGRAM................................................................................................................. 32 FIGURE 41.......................................................................................................................................... 32 FIGURE 42 - RECTIFIER OUTPUT WAVE ................................................................................................ 33 FIGURE 43- REAL VFD, THE SWITCHES SHOWN WOULD ACTUALLY BE TRANSISTORS. ........................... 34 FIGURE 44- THE BLUE SINE-WAVE IS SHOWN FOR COMPARISON PURPOSES ............................................ 34 FIGURE 45- METAL DETECTOR ........................................................................................................... 36 FIGURE 46- EDDY CURRENTS INDUCE THEIR OWN MAGNETIC FIELD ...................................................... 36 FIGURE 47- INDUCES A MAGNETIC FIELD ............................................................................................. 36 FIGURE 48- PROGRAMMABLE LOGIC CONTROLLER (PLC) ................................................................... 37 FIGURE 49- PLC ARCHITECTURE ........................................................................................................ 38 FIGURE 50- PLC SCAN CYCLE ............................................................................................................ 39
  • 8. 1 1 Introduction to the Training Establishment 1.1 History of the Ceylon Biscuit Limited William’s Biscuit Factory, the first biscuit factory in Sri Lanka was a small scale handmade biscuit venture owned by Mr. Williams. This factory was acquired in 1939 by Mr. Simon Arthur Wickramasingha and launched “Williams Confectionery” with just 10 employees. It was mechanized with Baker Perkins lines in 1957. Together with the Sri Lankan Government and CARE of USA, high-protein biscuits were manufactured by ‘Williams’ to supplement mid-day meals for school children of Sri Lanka. A biscuit factory was built for this purpose on eight acres of rubber land in Pannipitiya in 1968. The factory was operated by Ceylon Biscuits Limited (CBL) It launched its own brand name “Munchee”, which gradually invaded the biscuit market in late 1990s. (Ceylon Biscuits Limited, 2002) CBL has now become one of the largest privately-owned business groups of Sri Lanka with the inception of number of subsidiaries, which extended its territory in the food market. It now has gained a firm grip of the local market and an excellent global presence. 1.1.1 Nature of Business Figure 2 - CBL Group of Companies Figure 1 - Ceylon Biscuit Limited (1968)
  • 9. 2 CBL Foods International (PVT) Limited, is one of the best subsidiaries of the CBL Group which is a major foods manufacturing company in Sri Lanka incepted in 2002. It manufactures a range of confectionery products (rice cracker, chocolates, biscuits, wafers, cakes) under the brand names of Ritzbury, Munchee, Tiara and Kome. It is located on 200,000 square foot of land at Ranala, just 20 km away from the city of Colombo. Employee Strength of CBL Foods International (PVT) Ltd. • Total Employee: - 1200 • Direct Employee: - 400 • Manpower Employee: - 800 Figure 3 - CBL Foods International (PVT) Ltd Figure 4 - CBL Logo Figure 5 - Location of the Company
  • 10. 3 1.1.2 Departments of The Company There are 12 departments in CBL Foods International (PVT) Ltd which collectively contribute in goal achieving process. They are, • Production Department • Human Resources Department • Stores Department • Supply Department • Engineering Department • Quality Assurance Department • Projects and Safety Department • Marketing and Sales Department • Information Technology Department • Exports Department • New Product Development Department • Work Study Department 1.1.3 Production Plants of the Company There are 06 production plants in the establishment. They are, • Biscuit Plant • Rice Cracker Plant • Wafer Plant • Cake Plant • Chocolate Plant • Candy Bar Plant Figure 6 - Management Hierarchy of the Engineering Department
  • 11. 4 1.1.4 Organizational chart CBL Foods International (PVT) Ltd organizational hierarchy starts with Mr. Ramya Wickramasingha, The CBL group’s Chairman, The board of directors of the CBL group and the CEO of CBL Foods, Chairman Deputy Chairman Board of Directors Chief Executive Officer GM F & A AGM – WH & Log Mgr. - Sup Head of the Department of Quality Assurance QA Manager QA Executives QA Assistants QA Helpers Lab & Microbiology Manager Microbiological analyst Mgr. R&D HRM Mgr. Project Dev. & Safety Mgr. Prem. is & environ. Snr. Eng. Pro. GM P & E Eng. Asst. Eng. Mech anics Factory Mgr. Prod Mgr. Floor level work Figure 7 - Organizational Chart
  • 12. 5 1.2 Co – operate plan 1.2.1 Vision CBL groups’ collective vision is “to become the market leader in confectionary, in South Asia with a global presence and recognition”. 1.2.2 Mission A CBL group of company has no a clear stated mission rather achieving the marketing goals set for each product with the aid of company assets and the latest innovation and technology. 1.3 Management Practices SWOT Analysis is a useful technique for understanding Strengths and Weaknesses, and for identifying both the Opportunities open and the Threats in a project or a business venture. Strengths • Strong cooperative top management • Highly educated and capable staff with skills • Well trained and motivated junior staff and confident third-party employees. • Well established sales and distribution network in local and international market. • Strong brand images and “excellent sales force” • Enterprise Resources Planning systemized with SAP which enable the • management to have a better look on the plant performance. • Capability of doing research and development of products • Approach to minimize the frequency of breakdowns • Approach to increase energy and chemical saving. Figure 8 - Cooperate Vision and Mission
  • 13. 6 Weaknesses • Dependence on single suppliers for critical raw material (Wheat flour) • Low profit margins of some products • nobility to meet demand and inability of expanding the volume in some products due to • limited machinery availability and less employees. • Limited land availability • High wastage in some products • Water consumption per unit volume of product is high. • Unavailability of training personals due to their huge amount of work load. Opportunities • Rapidly Expanding Export Market • Growing of economy in Sri Lanka • Product Diversification • One of a key confectionary manufacture in Sri Lanka • Social influence Threats • Upcoming of competitors due to the inability of increment of production capacity with the demand fluctuation. • Information Technology Consulting Agreement (ITCA) with India. • Capability of global players entering the market capturing the chocolate market. • Price competition for high price sensitivity products in local market. • Upcoming of rivals with local formulas which attracts the local customers than the international formulas now applied in many products. Contribution to the Sri Lanka Society CBL Foods serves the country as the leading bakery and confectionery factory since 2002. For more than a decade, they have been manufacturing biscuits, chocolate and other products identifying consumer’s needs and wants while enriching the nation with their nutritional bakery products. Around 1200 people are employed in the factory including both company and man power workers. Other than man power, lot of services has been outsourced by the company which creates many more job opportunities indirectly. As a social responsibility, the CBL group conducts and sponsors in several educational, sports, art and
  • 14. 7 cultural events frequently. Providing the training opportunities such an event which enables the establishment to transfer their technology, experience and knowledge to the future work force of Sri Lanka. Administrative Practices Leave Structure • Annual leaves 14 • Casual leaves 7 1.3.1 Recruitment Procedure When required an employer for relevant division, the division manager inform to HR division. HR division should be publishing an application and the candidate ready to face relevant interview. The interview is conducting by structured interview panel. The interview is done by providing relevant field questionnaire, practical problems and evaluating past experience of the candidate. 1.3.1.1 Employees’ Provident Fund (EPF) The employees’ Provident Fund (EPF) the employees provident fund scheme basically covers almost all the employees in the private sector and the cooperation sectors. The main objective of this scheme is to provide social security or protection to employee at old stage inactivity or their dependent after death. All employees are registered under government approved EPF. 8% of the employee’s salary and 12% contributed by company will be remitted to the central Bank of Sri Lanka Employees’ Provident Found. Every employee contributing to the EPF is assigned a membership number. 1.3.1.2 Employees’ Trust Fund (ETF) The employees trust fund is administrated by the employees Trust Fund Board and at present the ETF board is functioning under the Ministry of Finance. The company will contribute an amount 3% of the employees’ salary to employees’ Trust Fund
  • 15. 8 1.3.1.3 Safety Practices Safety of the employers is the most critical aspect in industries. The management should be able to confirm the safety of the labors and the all staff with same attention to all. Safety analysis should be done before each activity and maintenance activities. In addition to that each of the people currently employing inside the factory should be aware of the safety precautions and the emergency actions that should be taken at relevant occasion. The advantages of good safety environment are prevention of deaths, injuries, financial losses and property damage, increasing worker productivity, enhancing product or service quality and promoting good public relations and etc. 1.3.1.4 Lockout-Tag out concept Lockout-tagout (LOTO) or lock and tag is a safety procedure used in industry and research settings to ensure that dangerous machines are properly shut off and not able to be started up again prior to the completion of maintenance or repair work. The LOTO concept is used in most branded companies in their premises and maintain it as their own standard. In this concept it ensures a safety and a protection for the labors, technicians and for the processes of the company. In industry it turns a higher consideration on LOTO concept and it is a must in some countries since the safety is first in all the time. In the CBL Foods International, Ranala uses this concept for their maintenance. The Lockout-tagout procedure is as follows. • Announce shut off • Identify the energy source • Isolate the energy source • Lock and tag the energy source. • prove that the equipment isolation is effective
  • 16. 9 1.4 Personal Protective Equipment (PPE) safety is the first thing in the industry. Proper safety equipment is helped to prevent any kind of damages. General Safety Equipment 1.4.1 Safety Equipment • Safety Helmet: It is used as a protection against injuries to a head, from falling or flying objects • Safety Goggles: It is used as a protection to the eye. While working in dusty places, the right type goggles should be used. • Safety Shoes: safety shoes were used for the protection of legs from injury. Figure 9 - Safety Helmet Figure 10 - Safety Googles Figure 11 - Safety Shoes
  • 17. 10 • Ear plugs/ Ear muffs: Hazardous noise in generator rooms, grinding areas, production areas • Electrical gloves are required when working in high and low voltage applications to protect workers from shock, burns, fires and explosions. Figure 12 - Ear Muffs Figure 13 - Electrical Gloves
  • 18. 11 1.4.2 Electrical safety symbols Table 1 - Safety Symbols signs and symbols Description Voltage Warning Labels Danger of death from electricity warning Switch off when not in use Electric shock warning Danger do not enter sign Warning to isolate before removing cover safety helmet must be worn sign
  • 19. 12 1.4.3 Electrical Safety clothing All electrician, and employees must understand and comply with safety standards related to electrical work and follow the uniform practices outlined in this document when engaged in electrical work. Here show what the Electrical safety clothing in workplace are, Figure 14 - Safety clothing
  • 20. 13 2 Training Experience I trained at Electrical department of CBL International PVT Ltd. During this 6-month implant training period I got lot of technician level and supervisor Level experience in transmission and distribution, motor controller, generator servicing, UPS system maintenance, wiring diagram inspection, Switchgears, testing…etc. First day of the training I was able to learn about safety instructions and introduction and identify tools in workshop. In the workshop, I learned about panel designing, Power Distribution System and wiring panel board according to the job requirement. And also, when I was in training period I have done some projects related to Compressed Air Energy Conservation, and Electrical and Electronics Equipment Repairing and Servicing Record, General Electrical Audit report, Etc. while I was in my training period I got lots of working experience with other Electricians but sometime working with them make was a little harder for me. But however, I was able to manage everything in a proper manner. Basically, electrical department is doing repair and maintenance on all of the electrical parts in the machineries and they also maintenance and service the power distribution system around the company. All the plants have various kinds of machinery and conveyor lines which use the best of technology that available. European machinery for manufacturing and Japanese machinery with very accurate weight control for packaging. Also there were fully automated continuous manufacturing process within a highly controlled environment. Especially in cake production plant, they use fully automated continuous manufacturing process with a class 100,000 clean room. Cakes are devoid of human contact during production and completely isolated from exterior environment. Most of the productions in the company are fully autonomous and others are being automated as well. In the complete training period I was able to learn about how to interact with colleagues and how to deal with the chain of command. I also observed about how the Electrical department operate, Which Individuals are responsible and equipped with dealing with specific tasks. In a company there are different peoples with different abilities and talents. As a Supervisor We need to be able task them with work that they are good at.
  • 21. 14 2.1 AC Power Distribution 2.1.1 Single phase wire system It is easier to balance the electrical loads of the network. single-phase connection, two wires come into your electrical service panel. There was standard color code. In single phase wiring system wire color changed since 2006, live cable to Brown and Neutral Cable to Blue color. Single phase wiring system mainly used in home appliances.230V phase voltage between (N) neutral live and (L) live wire. 2.1.2 Three phase wire system Three phase system is more suited to the consumption of a building that includes powerful machines. three-phase connection, 3 or 4 wires come into your electrical service panel. Most of the time, a voltage difference of 230 V separates each live wire from the neutral, while there is a voltage difference of 400 V between two live wires. This makes it possible to supply both the domestic cables with 230 V and machines requiring 400v. • Industrial use only • in three phase wiring system there were two methods. • Three wire method for motors and Four wire method for panel board wiring. Figure 15 - Wiring System Types Figure 16 - Old wire and New color code
  • 22. 15 2.1.3 Type of wire with their current carried capacity. Tabl2 - Current Carried Capacity Area (in mm2 ) Current carrying capacity ( in Amp) Number of wire and thickness of each wire 1 11 1/0.044 1.5 13 3/0.024 2.5 16 3/0.036 4 21 7/0.029 6 28 7/0.36 10 34 7/0.44 16 43 7/0.052 25 56 7/0.064 35 66 7/0.044 2.1.4 Cable Wire Protection Figure 17- Old wire and New Color Code Figure 18 - Cable Wire Insulation
  • 23. 16 1 - PVC jacket - Cable jacket is the first line of moisture, mechanical, flame and chemical defense for cable. 2 - braid shield - Braided shielding is a type of shielded cable that uses a tightly woven lattice of thin tin or copper wires to encapsulate a shielded cable assembly. 3 - Aluminum Mylar – This is used to protect the conductors from external frequencies. The shield also helps ==089keep in continuous contact with the drain wire. The drain wire picks up unwanted electricity and grounds, it. 4 – PVC insulation - PVC insulated wires have become so popular among electrical industries is because they are highly versatile 5 – Conductor – Conductor or group of conductors for transmitting electric power or telecommunication signals from one place to another 6 – Drain wire Drain wire is a part of a shield within a cable that reduces the resistance from any point on the shield to ground 2.1.5 DDLO (Drop Down Lift On) While I am in my training period. I could get experience with DDLO.it is a device that uses to protect Transformers, capacitor banks or electrical devises from high current surges and can consider it as a combination of fuse and a switch. This can provide a wide range of protection for overhead distribution system rated from 10kV to 36kV. Always DDLO connects in series with the transition line. For DDLO, standard voltage ratings are maintained between 11/12 kV ,22/24 kV ,33/36 kV. Fuse cutouts are capable of carries a maximum current of 100 A to 200A. Figure 19 - DDLO (Drop Down Life On)
  • 24. 17 2.1.5.1Positioning of the DDLO In Sri Lanka CEB practice is to position the DDLO before the Arresters along the high voltage circuit. (As shown in figure A) This concept ensures the safety of the workers who work on the transformer during the maintenance. (As the arrester is isolated when DDLO switch is opened) Figure 20 - Fuse Link Figure 21 - Fuse Link
  • 25. 18 2.2 What is Earth Fault Earth Fault is an inadvertent fault between the live conductor and the earth. When earth fault occurs, the electrical system gets short-circuited and the short-circuited current flows through the system. The fault current returns through the earth or any electrical equipment, which damages the equipment. It also interrupts the continuity of the supply and may shock the user. To protect the equipment and for the safety of people, fault protection devices are used in the installation. 2.2.1 How Earth Fault Protection Devices working The devices give the tripping command to break the circuit when earth fault occurs. The fault current is restricted and the fault is dispersed by the Restricted Earth Fault Protection (REFP) scheme. Normally earth fault relay, earth leakage circuit breaker and ground fault circuit interrupter, etc. are used to restrict the fault current. 2.2.2 Earth Fault Relay (EFR) It is a safety device used in electrical installations with high earth impedance. It detects small stray voltages on the metal enclosures of electrical equipment. The result is to interrupt the circuit if a dangerous voltage is detected. The EFR is protected against tripping from transients and prevents shock. 2.2.3 Earth Leakage Circuit Breaker The Earth Leakage Circuit Breaker detects the leakage current directly and prevents injury to humans and animals due to electrical shock. It is a voltage-sensing device and has recently been replaced by Residual Current Circuit Breaker (RCCB), which is a current sensing device. It is a special type of latching relay that is connected to the main power supply. When the fault current flows from live wire to the earth wire within the installation, the coil of ELCB senses the voltage and switches off the power. This requires a manual reset process to work again. The RCCB senses the leakage current and sends a signal to trip the system. Figure 22 - Earth Fault Relay
  • 26. 19 2.2.4 Ground Fault Circuit Interrupter The Ground Fault Circuit Interrupter is a safety device to prevent an electrical accident when any faulty tool is plugged in. It is a fast-acting circuit breaker to shut down the supply when the earth fault occurs within 1/40th of a second. It compares the incoming and outgoing current from the equipment along the circuit conductor. If there is any difference as little as 5 mA, GFCI restricts the current and trip quickly. GFCI does not help much with line contact hazards but protects from fire, overheating and destruction of wire insulation 2.2.5 Restricted Earth Fault Protection Scheme A star winding transformer, which is protected by a Restricted Earth Fault Protection with EFR protecting device as shown in the figure below. When an external fault F1 occurs in the network, I1 and I2 flow through the secondary side of the CTs. The resultant of I1 and I2 will be zero. However, if an internal fault F2 occurs inside the protective zone, only I2 flows and I1 is neglected. The resultant current I2 passes through the earth fault relay, which senses the fault current and protects the restricted portion of winding. The fault current is approximately 15% more than the rated winding current. To avoid the magnetizing inrush current, the stabilizing current must be in series with the relay. Figure 23- Earth Fault Protection with
  • 27. 20 2.2.6 Short Circuit Protection Devices To protect the devices and people from short circuit hazards, protecting devices are used in electrical circuits. These devices can detect the faults and trip the circuit immediately before the surge current reaches to the maximum. There are two popular protecting devices used frequently in every electrical circuit in industrial, let see in CBL. 2.2.7 Fuse Fuse is operated once in the circuit and then must be replaced after the trip occurs. It is helpful for phase by phase (single pole) protection. It offers a high breaking capacity at low volume, which limits electro- dynamic stress. 2.2.8 Circuit Breaker Circuit breakers can be reset either manually or automatically. It automatically breaks the circuit within a short cutoff time and separates the load from the power supply that protects the circuit from any damage. The magnetic triggers of CB open the poles. CBs limit both the thermal and thermodynamic effects. It works faster than a fuse. For example, Molded Case Circuit Breaker (MCCB), , Vacuum Circuit Breaker Figure 24 - Fuse
  • 28. 21 2.3 A Molded Case Circuit Breaker (MCCB) It is a type of electrical protection device that is used to protect the electrical circuit from excessive current, which can cause overload or short circuit. With a current rating of up to 2500A, MCCBs can be used for a wide range of voltages and frequencies with adjustable trip settings. These breakers are used instead of miniature circuit breakers (MCBs) in large scale PV systems for system isolation and protection purposes. 2.3.1 The Operates of MCCB The MCCB uses a temperature sensitive device (the thermal element) with a current sensitive electromagnetic device (the magnetic element) to provide the trip mechanism for protection and isolation purposes. This enables the MCCB to provide: 1) Overload Protection, 2) Electrical Fault Protection against short circuit currents, and 3) Electrical Switch for disconnection. Figure 25 - Molded Case Circuit Breaker (MCCB)
  • 29. 22 2.3.1.1Overload Protection Overload protection is provided by the MCCB via the temperature sensitive component. This component is essentially a bimetallic contact: a contact which consists of two metals that expand at different rates when exposed to high temperature. During the normal operating conditions, the bimetallic contact will allow the electric current to flow through the MCCB. When the current exceeds the trip value, the bimetallic contact will start to heat and bend away due to the different thermal rate of heat expansion within the contact. Eventually, the contact will bend to the point of physically pushing the trip bar and unlatching the contacts, causing the circuit to be interrupted. The thermal protection of the MCCB will typically have a time delay to allow a short duration of overcurrent which is commonly seen in some device operations, such as inrush currents seen when starting motors. This time delay allows the circuit to continue to operate in these circumstances without tripping the MCCB 2.3.1.2 Electrical Fault Protection against short circuit currents MCCBs provides an instantaneous response to a short circuit fault, based on the principle of electromagnetism. The MCCB contains a solenoid coil which generates a small electromagnetic field when current passes through the MCCB. During normal operation, the electromagnetic field generated by the solenoid coil is negligible. However, when a short circuit fault occurs in the circuit, a large current begins to flow through the solenoid and, as a result, a strong electromagnetic field is established which attracts the trip bar and opens the contacts. 2.4 Motor Protection Circuit Breaker (MPCB). Figure 26 - MPCB
  • 30. 23 In industrial MPCB are very important, so I got lot of experiences with when panel board wiring. Motor protection circuit breakers are a specialized type of electrical protection device that is designed specifically for electric motors, like their name implies. Electric motors have plenty of applications and are used to drive mechanical devices of all types, so it is very important to protect them adequately with MPCBs. The following are just a few examples of devices driven by electric motors in commercial and industrial buildings: • Rooftop air conditioners, chillers, compressors, heat pumps and cooling towers. • Extraction and injection fans, as well as air handling units. • Water pumping systems. • Elevators and other hoisting devices. • Industrial conveyor belts and other machinery used in manufacturing processes. The working condition of MPCB. It has bi-metallic strips in all three phases which gives overload protection. The bi metallic strip bends when current passing through increases from rated current due to heat generated by over current. The bending of bi metallic strip operates tripping mechanism of Circuit breaker. For short circuit protection it has electromagnetic coil. When current ratings increase say in kA ratings, the coil gets magnetized and hence the plunger pulls in which in turn operates the tripping mechanism of circuit breaker.
  • 31. 24 2.5 Contactor Contactors are very common things I have seen every panel board. Basically, contactor is an electrically- controlled switch used for switching an electrical power circuit. A contactor is typically controlled by a circuit which has a much lower power level than the switched circuit, such as a 24-volt coil electromagnet controlling a 230-volt motor switch. A contactor consists of an electromagnet, contacts and spring enclosed inside an enclosure. In some contactors, economizers are provided to reduce power consumption. Certain arrangements for arc extinction is also made inside for making and breaking the operation of contactors. Figure 27 - Contactor Figure 28- Conventional laminated soft iron Magnetic Core
  • 32. 25 2.5.1 Inside of Contactor Coil An electromagnet is a key component in contactors without which it cannot function. It requires an additional supply for excitation. It drains negligible current from the supply during excitation. These electromagnets will be hollow cylindrical in shape. A rod (armature) with spring return arrangement will be placed in the hollow cylindrical electromagnet. In some contactors, this electromagnet is split into two halves. One of the halves is fixed and the other is movable. Movable power contacts are fixed to the movable electromagnet. Under normal condition, these two halves of electromagnets are held apart using spring in between. In contactor with AC coil, the electromagnetic core is made up of laminated soft iron to reduce eddy current losses and in contactor with DC coil, the electromagnetic core is made up of solid steel/ soft ironic core since there is no risk of eddy current loss in DC. Working Condition of Contactor A contractor is very simple. Whenever the electromagnetic coil is energized, an electromagnetic field is produced. This electromagnetic field attracts the metallic rod (armature) towards the gap in the hollow cylindrical magnet. In contactors with split electromagnets, the movable half of the electromagnet is attracted towards the fixed electromagnet. This action closes the contacts. The contacts remain closed as long as the electromagnet remains excited. When the coil is de-energized, moving contact is pushed back to its normal position by the spring. Contactors are designed to open and close contacts rapidly. Moving contacts may bounce as it rapidly makes contacts with the fixed contacts. Bifurcated contacts are used in some contactors to avoid bouncing. The input to the contactor coil may be AC or DC (available in various voltage ranges starting from Figure 29- Conventional Low voltage contactor coil/ Conventional Low voltage contactor coil Solid Steel Core
  • 33. 26 12Vac/ 12Vdc to 690Vac). A small amount of power is drained by the contactor coil during its operation. Economizer circuits are used to reduce the power consumed by the contactor during its operation. Contactors with AC coils have shading coils. Otherwise, the contactor may chatter every time the alternating current crosses zero. Shading coils delay demagnetization of the magnetic core and avoids chattering. Shading is not required in DC coils as the flux produced is constant. Figure 30 - Inside working of contactor
  • 34. 27 2.6 Relay A relay is classified into many types, a standard and generally used relay is made up of electromagnets which in general used as a switch. Dictionary says that relay means the act of passing something from one thing to another, the same meaning can be applied to this device because the signal received from one side of the device controls the switching operation on the other side. So, relay is a switch which controls (open and close) circuits electromechanically. The main operation of this device is to make or break contact with the help of a signal without any human involvement in order to switch it ON or OFF. It is mainly used to control a high-powered circuit using a low power signal. Generally, a DC signal is used to control circuit which is driven by high voltage like controlling AC home appliances with DC signals from microcontrollers. 2.6.1 Design of relay An electromechanical relay is basically designed using few mechanical parts like Electromagnet, a movable armature, contacts, yoke, and a spring/frame/stand, these parts are showing in the internal pictures of Relay below. All these are arranged logically to form into a relay. 2.7 Encoder Figure 31 - Relay Figure 32 - Encoder
  • 35. 28 An encoder is a sensor of mechanical motion that generates digital signals in response to motion. As an electro-mechanical device, an encoder is able to provide motion control system users with information concerning position, velocity and direction. There are two different types of encoders: linear and rotary. A linear encoder responds to motion along a path, while a rotary encoder responds to rotational motion. An encoder is generally categorized by the means of its output. An incremental encoder generates a train of pulses which can be used to determine position and speed. An absolute encoder generates unique bit configurations to track positions directly. 2.7.1 Linear encoder linear encoder is a sensor, transducer or reading-head linked to a scale that encodes position. The sensor reads the scale and converts position into an analog or digital signal that is transformed into a digital readout. Movement is determined from changes in position with time. Both optical and magnetic linear encoder types function using this type of method. However, it is their physical properties which make them different. 2.7.2 Rotary Encoder A rotary encoder, also called a shaft encoder, is an electro-mechanical device that converts the angular position or motion of a shaft or axle to analog or digital output signals. There are two main types of rotary encoder: absolute and incremental Encoder Figure 33- Linear encoder
  • 36. 29 2.7.3 Incremental Encoder Incremental encoder is a glass disk, LED (light emitting diode), and a photo detector. The transparent disk contains opaque sections which are equally spaced to deflect light while the transparent sections allow light to be passed through shown in Figure 34 above. An optical encoder utilizes a light emitting diode which shines light through the transparent portions of the disk. The light that shines through is received by the photo detector which produces an electrical signal output. 2.7.4 Absolute encoders Absolute encoders have a unique code for each shaft position. Or in other words, every position of an absolute encoder is distinctive. The absolute encoder interprets a system of coded tracks to create position information where no two positions are identical. Figure 34 - Rotary Encoder Figure 35- Incremental and Absolute Encoder
  • 37. 30 2.8 Inductive sensor Inductive proximity sensors are used in many industrial processes, including food & beverage. Inductive sensors are those that detect metallic objects without coming in direct contact. Instead, they generate and use a high-frequency oscillating magnetic field. Inductive sensors use currents induced by magnetic fields to detect nearby metal objects. The inductive sensor uses a coil (an inductor) to generate a high frequency magnetic field as shown in Figure 37 below. If there is a metal object near the changing magnetic field, current will flow in the object. These work by setting up a high frequency field. If a target nears the field will induce eddy currents. These currents consume power because of resistance, so energy is in the field is lost, and the signal amplitude decreases. The detector examines filed magnitude to determine when it has decreased enough to switch. The sensors can detect objects a few centimeters away from the end. But, the direction to the object can be arbitrary as shown in Figure 38 below. Figure 36 - Inductive Sensor Figure 37- Inductive proximity sensor
  • 38. 31 The magnetic field of the unshielded sensor covers a larger volume around the head of the coil. By adding a shield (a metal jacket around the sides of the coil) the magnetic field becomes smaller, but also more directed. Shields will often be available for inductive sensors to improve their directionality and accuracy 2.9 VFD (Variable Frequency Drive) AC motor speed is controlled in two ways – either by controlling the voltage or frequency. Frequency controlling gives better control due to constant flux density than voltage control. This is where the working of VFDs comes to play. It is a power conversion device which converts the fixed voltage, fixed frequency of the input power to the variable voltage, variable frequency output to control AC induction motors. It consists of power electronic devices (like IGBT, MOSFET), high speed central controlling unit (such as microprocessor, DSP) and optional sensing devices depending on the application used. Most of the industrial applications require variable speeds at peak load conditions and constant speeds at normal operating conditions. Closed loop working of VFDs maintain the speed of motor at constant level, even in case of input and load disturbances. The two main features of variable frequency drive are adjustable speeds and soft start/stop capabilities. These two features make VFD’s a powerful controller to control the AC motors. VFD consists of mainly four sections; those are rectifier, intermediate DC link, inverter and controlling circuit. Figure 38 - Shielded and Unshielded sensors Figure 39- Variable Frequency Drive
  • 39. 32 The first stage of a Variable Frequency AC Drive, or VFD, is the Converter. The converter is comprised of six diodes, which are similar to check valves used in plumbing systems. They allow current to flow in only one direction; the direction shown by the arrow in the diode symbol. For example, whenever A- phase voltage (voltage is similar to pressure in plumbing systems) is more positive than B or C phase voltages, then that diode will open and allow current to flow. When B-phase becomes more positive than A-phase, then the B-phase diode will open and the A-phase diode will close. The same is true for the 3 diodes on the negative side of the bus. Thus, we get six current “pulses” as each diode opens and closes. This is called a “six-pulse VFD”, which is the standard configuration for current Variable Frequency Drives. Figure 40- VFD diagram Figure 41
  • 40. 33 Assume that the drive is operating on a 480V power system. The 480V rating is “rms” or root-mean- squared. The peaks on a 480V system are 679V. As you can see, the VFD dc bus has a dc voltage with an AC ripple. The voltage runs between approximately 580V and 680V. AC ripple on the DC bus by adding a capacitor. A capacitor operates in a similar fashion to a reservoir or accumulator in a plumbing system. This capacitor absorbs the ac ripple and delivers a smooth dc voltage. The AC ripple on the DC bus is typically less than 3 Volts. Thus, the voltage on the DC bus becomes “approximately” 650VDC. The actual voltage will depend on the voltage level of the AC line feeding the drive, the level of voltage unbalance on the power system, the motor load, the impedance of the power system, and any reactors or harmonic filters on the drive. The diode bridge converter that converts AC-to-DC, is sometimes just referred to as a converter. The converter that converts the dc back to ac is also a converter, but to distinguish it from the diode converter, it is usually referred to as an “inverter”. It has become common in the industry to refer to any DC-to-AC converter as an inverter. Figure 42 - Rectifier output wave
  • 41. 34 When we close one of the top switches in the inverter, that phase of the motor is connected to the positive dc bus and the voltage on that phase becomes positive. When we close one of the bottom switches in the converter, that phase is connected to the negative dc bus and becomes negative. Thus, we can make any phase on the motor become positive or negative at will and can thus generate any frequency that we want. So, we can make any phase be positive, negative, or zero. Figure 43- Real VFD, the switches shown would actually be transistors. Figure 44- The blue sine-wave is shown for comparison purposes
  • 42. 35 The output from the VFD is a “rectangular” wave form. VFD’s do not produce a sinusoidal output. This rectangular waveform would not be a good choice for a general purpose distribution system, but is perfectly adequate for a motor. If we want to reduce the motor frequency to 30 Hz, then we simply switch the inverter output transistors more slowly. But, if we reduce the frequency to 30Hz, then we must also reduce the voltage to 240V in order to maintain the V/Hz ratio (see the VFD Motor Theory presentation for more on this). How are we going to reduce the voltage if the only voltage we have is 650VDC? This is called Pulse Width Modulation or PWM. Imagine that we could control the pressure in a water line by turning the valve on and off at a high rate of speed. While this would not be practical for plumbing systems, it works very well for VFD’s. Notice that during the first half cycle, the voltage is ON half the time and OFF half the time. Thus, the average voltage is half of 480V or 240V. By pulsing the output, we can achieve any average voltage on the output of the VFD. 2.9.1 Advantage of VFD • Reduce Energy Consumption and Energy Costs • increase Production Through Tighter Process Control. • Extend Equipment Life and Reduce Maintenance. 2.9.2 Application of VFD • Safe Acceleration. • Emergency bypass capability • Energy saving on most pump and fan application. • Better process control and regulation. • Speeding up or slowing down a machine or process
  • 43. 36 2.10 Metal detector In CBL International Plant every full finished product finally will go through metal detector. Its mean there are so many metal detectors. Food Industry. Metal Detectors detect metal contaminants accidentally present on industrial products, with levels of sensitivity, immunity to interference and response speeds designed to satisfy the strictest Quality Control requirements. Metal Detectors sense and remove the presence of ferrous, non-ferrous and stainless metals in the process flow in-line, in free- fall applications, and in conjunction with conveyors. These units also find metal encapsulated in the individual particle. Successful detection and separation of metal will protect that processing equipment from damage, which saves your organization money and down time. The operation of metal detectors is based upon the principles of electromagnetic induction. Metal detectors contain one or more inductor coils that are used to interact with metallic elements on the ground. The single-coil detector illustrated below is a simplified version of one used in a real metal detector. Figure 45- Metal Detector Figure 47- Induces a magnetic field Figure 46- Eddy currents induce their own magnetic field
  • 44. 37 A pulsing current is applied to the coil, which then induces a magnetic field shown in blue. When the magnetic field of the coil moves across metal, such as the coin in this illustration, the field induces electric currents (called eddy currents) in the coin. The eddy currents induce their own magnetic field, shown in red, which generates an opposite current in the coil, which induces a signal indicating the presence of metal. 2.11 Programmable Logic Controller (PLC) Programmable Logic Controller (PLC) is a special computer device used in industrial control systems. Due to its robust construction, exceptional functional features like sequential control, counters and timers, ease of programming, reliable controlling capabilities and ease of hardware usage – this PLC is used as more than a special-purpose digital computer in industries as well as in other control-system areas. Most of the industries abbreviate these devices as “PC” but it is also used for personal computers; due to this, many manufacturers named these devices as PLCs. The programmable logic controller is used not only for industrial purpose but also in civil applications such as washing machine, elevators working and traffic signals control. Different types of PLCs from a vast number of manufacturers are available in today’s market. Therefore, in the following paragraphs, let us study about programmable logic controller’s basics, principles and applications. Programmable Logic Controllers are used for continuously monitoring the input values from sensors and produces the outputs for the operation of actuators based on the program. Every PLC system comprises these three modules: • CPU module • Power supply module • One or more I/O module Figure 48- Programmable Logic Controller (PLC)
  • 45. 38 2.11.1 PLC Architecture 2.11.2 CPU Module: A CPU module consists of central processor and its memory. The processor is responsible for performing all the necessary computations and processing of data by accepting the inputs and producing the appropriate outputs. 2.11.3 Power Supply Module: This module supplies the required power to the whole system by converting the available AC power to DC power required for the CPU and I/O modules. The 5V DC output drives the computer circuitry. 2.11.4 I/O Modules: The input and out modules of the programmable logic controller are used to connect the sensors and actuators to the system to sense the various parameters such as temperature, pressure and flow, etc. These I/O modules are of two types: digital or analog. 2.11.5 Communication Interface Modules: These are intelligent I/O modules which transfers the information between a CPU and communication network. These communication modules are used for communicating with other PLC’s and computers, which are placed at remote place or far-off locate. Figure 49- PLC Architecture
  • 46. 39 The program in the CPU of programmable logic controller consists of operating system and user programs. The purpose of the operating system with CPU is to deal with the tasks and operations of the PLC such as starting and stopping operations, storage area and communication management, etc. A user program is used by the user for finishing and controlling the tasks in automation. The Principle of operation of the PLC can be understood with the cyclic scanning also called as scan cycle, which is given in the below figure 50 Typical PLC scans cycle includes of the following steps: • The operating system starts cycling and monitoring of time. • The CPU starts reading the data from the input module and checks the status of all the inputs. • The CPU starts executing the user or application program written in relay-ladder logic or any other PLC-programming language. • Next, the CPU performs all the internal diagnosis and communication tasks. • According to the program results, it writes the data into the output module so that all outputs are updated. • This process continues as long as the PLC is in run mode. Figure 50- PLC Scan Cycle
  • 47. 40 2.11.6 Application of PLC automation system As one of the most technology enabled FMCG companies in Sri Lanka, CBL manufactures varied food products in state-of-the art facilities. By using PLC automation in a fully automated continuous manufacturing process with a class 100,000 clean room, cakes are devoid of human contact during production. They have a modern plant & equipment for the automation of the complete production process of soy-based foods. Production includes American machinery and is a fully automated continuous manufacturing process within a highly controlled environment.
  • 48. 41 3 CONCLUSION TO THE REPORT The industrial training is a compulsory part of our diploma program, which is offered by University College of Ratmalana This is a very valuable opportunity for all the students who are following the diploma program. It is offered by University College of Ratmalana with NAITA.our practical knowledge on industrial techniques and procedures were poor. Though we gained a good theoretical knowledge on various subject areas, our practical knowledge is not at an appreciative level. It is better when we are familiar with how the theories we learn would be applied in the industry. It is a remarkable point of the Diploma program, to gain 6 months’ experience in the industry. Opportunity, we gained to absorb the knowledge from experts in various subject areas was extremely valuable. Also, the ability to face interviews and social skills acquire a great improvement due to this opportunity. It should be mentioned that the knowledge gained during the course of the training was not strictly restricted to my chosen disciple. This I see as one of the best things about the training since it allowed us to explore and familiarize ourselves with numerous practical aspects found in a real industrial site. To elaborate, some examples would be the knowledge of organizational arrangement and hierarchy that was gained through the training. This knowledge would be found indispensable on a future date when working as a professional. As conclusion I would like to summarize the jobs, I have done at CBL Foods International (Pvt) Ltd. As major projects I can mention the Electrical and Electronics Equipment Repairing and Servicing Record, General Electrical Audit report, Compressed Air Energy Conservation project through that project I could calculate and identified what are compressed air wasting condition how much Electricity waste for it. For that I had to visit every corner of the plant and observe the current company Compressed air system and what are areas compressed air wasting. I learnt a lot from these projects. Apart from the vast amount of technical knowledge which we could gain from the training, it did another great service in allowing us to learn how to conduct ourselves in a professional manner which would be found a particularly useful skill in the future. This was the first instance where we were expected to display true professional behavior and we were given responsibilities to handle. In my opinion, the development of this aspect of our personalities was just as useful as the development of technical knowledge. Thus, the industrial training may be justly described as a most necessary process in the path to become a professional.
  • 49. 42 4 REFERENCE • [1] [1] LMD. (2018). CEYLON BISCUITS LIMITED LMD. [online] Available at https://lmd.lk/ceylon-biscuits-limited-3/ [Accessed 01 August 2019]. • [2] Daily Dairy of the NITA • [3] Refer the NITA record book. • [4] (2008), IET wiring Regulation, Requirements for Electrical installations, UK • [5] Theraja, B.L, (2005), A text book of Electrical technology, S. Chand & company LTD, Ram nagar,New Delhi, India
  • 50. 43 CERTIFICATION Name of the trainee : - B.A.D.Idumal ID No : - Address : - Institute & Address : - University Collage of Rathmalana Programme : - Electrical Technology (NVQ5, NVQ6) Training Organization and Address : - CBL Foods International (pvt) Ltd Habarakada road, Ranala, Training period : - 01.08.2019 to 07.08.2019 This is to certify that this report is prepared by myself under the training conduct at above organization. ……………………… ………………………. Date Signature of the trainee This is to certify that this report is prepared by above trainee under my regular supervision. ……………………… ……………………….
  • 51. 44 Date Signature of the Employer with stamp