NVQ 6 Electrical Technology Industrial Training Report

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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.P.S.Jayaneththi
Student Number : RT/ECT/F/17/1/0024
Course : Higher National Diploma in Electrical Technology
Field : Electrical Technology
Period : 06 months

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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) for organizing such a valuable industrial training program for me. Without them I
won't be able to get such a valuable training experience.
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 Eng. Upali Jayasiri, Senier Engnier – Electrical, Mr. Sarath Ranatunga, Senior Engineering
executive and other all Engineers, Supervisors and Technicians at CBL Foods international (pvt) Ltd,
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 this
industrial training period a success.
B.P.S.Jayaneththi
Higher National Diploma,
Department of Electrical Technology,
University Collage of Rathmalana.

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PREFACE
In this report, the experience and knowledge that I have gained during my first industrial training
program has been included. The way I 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 18th February to 10th September 2019.
During these 6 month of training period, I was able to interact with engineers, assistant engineers and
technicians which helped me to acquire immense theoretical and practical knowledge about industrial
environment. In this report, I have 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’ve done during the training period.
The third or final chapter includes the conclusion of the report. This conclusion includes an assessment
on the current Industrial Program.

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TABLE OF CONTENT
CHAPTER 01 .................................................................................................................. 1
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 Electrical safetysymbols........................................................................................ 11
1.4.3 Electrical Safety clothing.................................................................................... 12
CHAPTER 02 ................................................................................................................ 13
2 TRAINING EXPERIENCE .................................................................................. 13
2.1 INDUSTRIAL AUTOMATION.............................................................................................. 14
2.1.1 What is Industrial Automation ........................................................................... 14
2.1.2 Advantages of an Automation System ............................................................... 14
2.1.3 Parts of an Automation System .......................................................................... 15
2.1.3.2 CONTROL SYSTEM ELEMENTS..................................................................................... 19
2.1.4 Communication protocols used by Automation systems ................................... 22
2.2 MOTOR CONTROLLING.................................................................................................... 23
2.2.1 VFD (Variable Frequency Drive)....................................................................... 23
2.2.2 Advantage of VFD.............................................................................................. 24
2.2.3 Application of VFD............................................................................................ 24
2.3 PROJECTS I WAS TASKED WITH IN MY TRAINING PERIOD.................................................. 25
2.3.1 Auto Coating Machine Electrical panel replacement project............................. 25
2.3.2 Arduino Alarm clock project.............................................................................. 35
2.3.3 200I Coaxial Emulsifying Mixer drawing.......................................................... 37

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CHAPTER 03 ................................................................................................................ 41
3 CONCLUSION TO THE REPORT..................................................................... 41
4 REFERENCE ......................................................................................................... 43
ABBREVIATIONS ....................................................................................................... 44
List of Table
Table 1 - Safety Symbols ....................................................................................................................... 11
Table 2 - Communication protocols and there parameter...................................................................... 22

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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 - Lockout TAG........................................................................................................................... 8
Figure 10 - Safety Helmet ........................................................................................................................ 9
Figure 11 - Safety Googles....................................................................................................................... 9
Figure 12 - Safety Shoes .......................................................................................................................... 9
Figure 13 - Ear Muffs............................................................................................................................. 10
Figure 14 - Electrical Gloves ................................................................................................................. 10
Figure 15 - Safety clothing..................................................................................................................... 12
Figure 16 - PLC Controlled Automation System................................................................................... 14
Figure 17 - Hierarchy of an Industrial Automation System................................................................... 15
Figure 18 - RTD Sensor ......................................................................................................................... 16
Figure 19 - Thermocouples .................................................................................................................... 16
Figure 20 - Inductive sensors ................................................................................................................. 17
Figure 21 - Capacitive sensors ............................................................................................................... 18
Figure 22 - Photoelectric / Ultrasonic Sensing Setups........................................................................... 18
Figure 23 - Eye mark Sensor.................................................................................................................. 19
Figure 24 - Eye mark in a product.......................................................................................................... 19
Figure 25 - PLC Operation..................................................................................................................... 20
Figure 26 - Mitsubishi PLC.................................................................................................................... 20
Figure 27 - PLC Scan cycle.................................................................................................................... 21
Figure 28 - Programmable Automation Controllers .............................................................................. 21
Figure 29 - Parts of an Induction Motor................................................................................................. 23
Figure 30 - Circuit Diagram of a VFD.................................................................................................. 23
Figure 31 - Varied output frequencies with different duty cycle ........................................................... 24
Figure 32 - Previously Installed system ................................................................................................. 25
Figure 33- Proposed panel...................................................................................................................... 26
Figure 34 - Proposed panel layout, Enclosure....................................................................................... 27
Figure 35 - Proposed panel layout , Cable duct placement................................................................... 28
Figure 36 - Proposed panel Layout, Component placement .................................................................. 29

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Figure 37 - proposed panel, Main MCCB.............................................................................................. 30
Figure 38 - Proposed panel, 0.5KW Motor wiring ................................................................................ 31
Figure 39 - Proposed panel, 4KW motor wiring.................................................................................... 32
Figure 40 - Proposed panel, Air blower motor....................................................................................... 33
Figure 41 - Proposed panel, Required component list ........................................................................... 34
Figure 42 - Designed prototype board.................................................................................................... 35
Figure 43 - PCB Designed by Eagle 9.0.1 ............................................................................................. 36
Figure 44 - PCB after etching ................................................................................................................ 36
Figure 45 - PCB toner transferred clad board ........................................................................................ 36
Figure 47 - PCB after cleaning, drilling and soldering .......................................................................... 37
Figure 47 - PCB 2 boards mounted on each other ................................................................................. 37
Figure 48 - Emulsifying mixer panel wile inspecting the wiring........................................................... 37
Figure 49 - Emulsifying mixer panel dialers and controls..................................................................... 38
Figure 50 - Coaxial Emulsifying Mixer designed panel ........................................................................ 38
Figure 51 - Coaxial Emulsifying Mixer designed panel wiring diagram............................................... 39
Figure 52 - Coaxial Emulsifying Mixer designed panel wiring............................................................. 40

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Chapter 01
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.
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 1 - Ceylon Biscuit Limited (1968)
Figure 2 - CBL Group of Companies
CBL Bangladesh (Pvt) Ltd
- Bangladesh
CBL
Group
Ceylon Biscuits
Limited -
Pannipitiya
CBL Foods
International (Pvt)
Ltd - Ranala
CBL Natural Foods
(Pvt) Ltd -
Minuwangoda
Convenience Foods
(Lanka) PLC -
Rathmalana
Plenty Foods (Pvt)
Limited - Kundasale CBL Export (Pvt) Ltd -
Awissawella
CBL Agro Processors (Pvt) Ltd -
Mahiyanganaya
CBL Cocos (Pvt) Ltd -
Alawwa
CBL Global Foods (Pvt) Ltd -
Alawwa
CBL Mynmar -
Mynmar
SPAR -
Supermarket

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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

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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

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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

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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

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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.

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As a social responsibility, the CBL group conducts and sponsors in several educational, sports, art and
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

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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-Tagout 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
Figure 9 - Lockout TAG

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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 10 - Safety Helmet
Figure 11 - Safety Googles
Figure 12 - Safety Shoes

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 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 13 - Ear Muffs
Figure 14 - Electrical Gloves

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1.4.2 Electrical safetysymbols
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

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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 15 - Safety clothing

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Chapter 02
2 Training Experience
I trained at Electrical department of CBL Foods International PVT Ltd. During this 6-month implant
training period I got lot of technician level and supervisor Level experience in Industrial Automation,
Motor controlling, Electrical Troubleshooting and maintenance, Wiring diagram inspection,
Switchgears, Testing, Brief idea about Power Distribution System Generators and Transformers, …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, Industrial Automation, PLC, HMI, VFD, Servo Drive
programming and configuration, Power Distribution system, wiring panel boards and their components
according to the job requirement. And also, when I was in training period I have done some projects
such as Auto Coating Machine Electrical panel replacement project, Box Board machine drawing,200I
Coaxial Emulsifying Mixer drawing, Alarm Clock project, etc...
Basically, electrical department is doing repair and maintenance on all of the electrical parts of 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
available. European and Italian 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 using a pressurized room. 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.

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2.1 Industrial Automation
2.1.1 What is Industrial Automation
Industrial automation is the use of control systems, such as computers or robots, and information
technologies for handling different processes and machineries in an industry to replace a human being.
It is the second step beyond mechanization in the scope of industrialization. Today’s highly increasing
competitiveness over the industry demands high quality and most consistent products with a competitive
price. To address this challenge number of industries considering various new product designs and
integrated manufacturing techniques in parallel with the use of automated devices.
These automation devices include PLCs, PCs, PACs etc. and technologies include various industrial
communication systems.
2.1.2 Advantages of an Automation System
 To increase productivity
Automation of factory or manufacturing or process plant improves production rate through a better
control of production. It helps to produce mass production by drastically reducing assembly time per
product with a greater production quality. Therefore, for a given labor input it produces a large amount
of output.
Figure 16 - PLC Controlled Automation System

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 To provide optimum cost of operation
Integration of various processes in industry with automated machineries, minimizes cycle times and
effort and hence the need of human labor gets reduced. Thus the investment on employees has been
saved with automation.
 To improve product quality
Since the automation reduces the human involvement, the possibility of human errors also gets
eliminated. Uniformity and product quality with a greater conformity can be maintained with automation
by adaptively controlling and monitoring the industrial processes in all stages right from inception of a
product to an end product.
 To reduce routine checks
Automation completely reduces the need for manual checking of various process parameters. By taking
advantage of automation technologies, industrial processes automatically adjust process variables to set
or desired values using closed loop control techniques. Why Industrial Automation
 To raise the level of safety
Industrial automation increases the level of safety to personnel by substituting them with automated
machines in hazardous working conditions. Traditionally, industrial robots and robotic devices are
implemented in such risky and hazardous places.
2.1.3 Parts of an Automation System
Industrial automation systems can be very complex in nature, having large number of devices working
in synchronization with automation technologies. The figure below describes the levels of the
automation system consisting of different hierarchical levels.
Figure 17 - Hierarchy of an Industrial Automation System

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There are 3 basic parts of an Industrial Automation System.
 Sensing and Actuating Elements
 Control System Elements
 Supervisory Control Elements
2.1.3.1Sensing and Actuating Elements
The sensors or sensing elements convert the physical process variables such as flow, pressure,
temperature, etc. into electrical form. Various sensors include thermocouples, Resistor Temperature
Detectors (RTDs), strain gauges, etc. The signals from these sensors are used for processing, analyzing,
and decisions in order to produce the control output. The various control techniques are implemented to
produce the required output by comparing the current sensed process variable with set values. Finally,
the controllers produce the computed outputs and are applied as electrical or pneumatic signal inputs to
the actuating elements. Actuators convert the electrical or pneumatic signals to the physical process
variables. Some of the actuators include control valves, relays, motors, etc.
2.1.3.1.1Temperature Sensors
Monitoring and controlling temperature is essential in a variety of process control and industrial
automation applications. There are a variety of temperature that work on different principles.
 Thermocouples are the most commonly used type of temperature sensor. Thermocouples are self-
powered, require no excitation, can operate over a wide temperature range, and have quick response times.
Thermocouples are made by joining two dissimilar metal wires together. This causes a Seebeck Effect.
The Seebeck Effect is a phenomenon in which a temperature difference of two dissimilar conductors
produces a voltage difference between the two substances. It is this voltage difference that can be
measured and used to calculate the temperature.
Figure 19 - Thermocouples Figure 18 - RTD Sensor

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 The working of the RTD sensor is based on the resistance- temperature relationship of the material used
for its construction. The amount of change seen in the resistance value of the material caused due to per
degree rise in temperature is measured and the sensor is calibrated accordingly.
2.1.3.1.2 Proximity Sensors
Proximity sensors detect the presence or absence of objects using electromagnetic fields, light, and
sound. There are many types, each suited to specific applications and environments.
 Inductive sensors
 Capacitive sensors
 Photoelectric sensors
 Through-beam
 Retro-reflective
 Diffuse
 Ultrasonic sensors
 Inductive sensors, these non-contact proximity sensors detect ferrous targets, ideally mild steel thicker
than one millimeter. The oscillator creates a symmetrical, oscillating magnetic field that radiates from
the ferrite core and coil array at the sensing face. When a ferrous target enters this magnetic field, small
independent electrical currents called eddy currents are induced on the metal’s surface. This changes the
reluctance (natural frequency) of the magnetic circuit, which in turn reduces the oscillation amplitude.
 Capacitive sensors, Capacitive proximity sensors can detect both metallic and non-metallic targets in
powder, granulate, liquid, and solid form. This, along with their ability to sense through nonferrous
materials, makes them ideal for sight glass monitoring, tank liquid level detection, and hopper powder
level recognition.
Capacitive sensors, the two conduction plates (at different potentials) are housed in the sensing head
and positioned to operate like an open capacitor. Air acts as an insulator; at rest there is little
capacitance between the two plates. As a target enters the sensing zone the capacitance of the two
plates increases, causing oscillator amplitude change.
Figure 20 - Inductive sensors

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 Photoelectric sensors, Photoelectric sensors are so versatile that they solve the bulk of problems put to
industrial sensing. Because photoelectric technology has so rapidly advanced, they now commonly detect
targets less than 1 mm in diameter, or from 60 m away. Classified by the method in which light is emitted
and delivered to the receiver, many photoelectric configurations are available. However, all photoelectric
sensors consist of a few of basic components: each has an emitter light source (Light Emitting Diode,
laser diode), a photodiode or phototransistor receiver to detect emitted light, and supporting electronics
designed to amplify the receiver signal. The emitter, sometimes called the sender, transmits a beam of
either visible or infrared light to the detecting receiver.
 Ultrasonic proximity sensors are used in many automated production processes. They employ sound
waves to detect objects, so color and transparency do not affect them (though extreme textures might).
This makes them ideal for a variety of applications, including the long-range detection of clear glass and
plastic, distance measurement, continuous fluid and granulate level control, and paper, sheet metal, and
wood stacking. The most common configurations are the same as in photoelectric sensing: through beam,
retro-reflective, and diffuse versions.
Figure 21 - Capacitive sensors
Figure 22 - Photoelectric / Ultrasonic Sensing Setups

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2.1.3.1.3 Eye mark Sensor
An ‘eye mark’ (also known as ‘eye spot’) is a small rectangular printed area located near the edge of the
printed flexible packaging material. A sensor on the form-fill-seal (FFS) machine reads the eye mark to
identify packaging material, control the material’s position, and coordinate the separation and cutting of
the flexible packaging material. To package products with flexible packaging, the printed material is
supplied on a continuous roll and fed into the FFS machine where the sensor reads the eye mark to
indicate when to cut individual units, fold the material, seal the sides (creating the packaging’s shape),
fill with the product, and then seal the final side.
2.1.3.2Control System Elements
These are the microprocessor-based electronic controllers or simply industrial computers that accept the
signals from various sensors as well as command signals from supervisory systems or from human
operators. These controllers can be continuous control systems or sequential/logic control depends on
the structure of control nature. The controller processes the sensing values and supervisory values and
depends on the control structure, it produces the control output to various actuating devices. There are
few types of Control Elements.
 Programmable Logic Controller (PLC)
 Programmable automation controllers (PACs)
Figure 23 - Eye mark Sensor
Figure 24 - Eye mark in a product

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2.1.3.2.1 Programmable Logic Controller (PLC)
A Programmable Logic Controller, or PLC, is a ruggedized computer used for industrial automation.
These controllers can automate a specific process, machine function, or even an entire production line.
The PLC receives information from connected sensors or input devices, processes the data, and triggers
outputs based on pre-programmed parameters. Depending on the inputs and outputs, a PLC can monitor
and record run-time data such as machine productivity or operating temperature, automatically start and
stop processes, generate alarms if a machine malfunctions, and more. Programmable Logic Controllers
are a flexible and robust control solution, adaptable to almost any application.
The operation of a PLC is very simple. The processor makes decisions based on a ladder logic program
written by the user. In order to use the program properly, the PLC must communicate with the various
field devices it is tasked with monitoring and controlling. It then compares the actual conditions of the
field devices with what the program instructs them to do, and updates the output devices accordingly.
 The Scan Cycle
PLCs operate by continually scanning programs and repeat this process many times per second. When
a PLC starts, it runs checks on the hardware and software for faults, also called a self-test. If there are
no problems, then the PLC will start the scan cycle. The scan cycle consists of three steps: input scan,
executing program(s), and output scan.
Input Scan: A simple way of looking at this is the PLC takes a snapshot of the inputs and solves the
logic. The PLC looks at each input card to determine if it is ON or OFF and saves this information in a
data table for use in the next step. This makes the process faster and avoids cases where an input changes
from the start to the end of the program.
Figure 26 - Mitsubishi PLC
Figure 25 - PLC Operation

21
Execute Program (or Logic Execution): The PLC executes a program one instruction at a time using
only the memory copy of the inputs the ladder logic program. For example, the program has the first
input as ON. Since the PLC knows which inputs are ON/OFF from the previous step, it will be able to
decide whether the first output should be turned ON.
Output Scan: When the ladder scan completes, the outputs are updated using the temporary values in
memory. The PLC updates the status of the outputs based on which inputs were ON during the first step
and the results of executing a program during the second step. The PLC now restarts the process by
starting a self-check for faults.
2.1.3.2.2 Programmable Automation Controllers (PACs)
PACs have an open architecture and incorporate modular design. This helps an array of devices,
networks, and systems communicate and operate with each other. PACs are used to communicate,
monitor, and control equipment across multiple networks and devices. This is possible because they
utilize standard protocols and network technologies such as Ethernet and Structured Query Language
(SQL).
Thanks to their modular design, PACs help simplify system expansion processes. Adding or removing
components is easier to execute. PACs have the ability to monitor and control thousands of I/O points
in addition to offering tag-based programming. With tag-based programming, a single tag-name
database is used for development, and these tags can be assigned to a variety of functions before being
tied to a specific I/O.
Figure 27 - PLC Scan cycle
Figure 28 - Programmable Automation Controllers

22
2.1.4 Communication protocols used by Automation systems
There are mainly multiple communication protocols for communicating with PLCs. The communication
protocols are depended upon three fundamental parts as Baud rate, Network length, Number of nodes.
 Ethernet
 Profibus
 RS-232
 RS-485
 Multi-Point Interface (MPI)
 Point to Point (PPI)
 Data Highway (DH)
 Control Net
 Device Net
 USB Adapter
 PC Adapter
Table 2 - Communication protocols and there parameter
Sr.
No.
Protocol Baud Rate Network Length
Number of
Nodes
1 Ethernet 100 Mb/s
Few Kilometers
(based on the type
of Ethernet)
255
2 Profibus 5- 12 Mb/s 15 Km 127
3 RS-232 19.2 Kb/s 10 m 1
4 RS-485 10 Mb/s 1.2 Km 32
5 MPI 19.2 – 38.4 Kb/s 50 m 32
5 PPI 187.5 Kb/s 500 m 1
6 DH 230.4 Kb/s 3.048 Km 64
7 Control Net 5 Mb/s 30 Km 99
8 Device Net 500 Kb/s 0.487 64
9 USB Adapter 57.6 Kb/s 10 m 1
10 PC Adapter 9600 Kb/s 15 m 1

23
2.2 Motor Controlling
An induction motor (also known as an asynchronous motor) is a commonly used AC electric motor. In
an induction motor, the electric current in the rotor needed to produce torque. current in the rotor is
obtained via electromagnetic induction from the rotating magnetic field of the stator winding.
2.2.1 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 29 - Parts of an Induction Motor
Figure 30 - Circuit Diagram of a VFD

24
2.2.2 Advantage of VFD
 Reduce Energy Consumption and Energy Costs
 Increase Production Through Tighter Process Control.
 Extend Equipment Life and Reduce Maintenance.
2.2.3 Application of VFD
 Safe Acceleration.
 Energy saving on most pump and fan application.
 Better process control and regulation.
 Speeding up or slowing down a machine or process
.
Figure 31 - Varied output frequencies with different duty cycle

25
2.3 Projects I was tasked with in my training period
In the training period I was tasked with various kind of projects. Some of them are
 Auto Coating Machine Electrical panel replacement project.
 Alarm Clock project
 200I Coaxial Emulsifying Mixer drawing.
 Box Board packeting machine drawing.
 Tray Feeder conveyor automation project.
2.3.1 Auto Coating Machine Electrical panel replacement project.
At the time the auto coating machine in the chocolate plant was in need of a new electrical panel. The
existing panel was very old and full of issues. When I was observing the panel I noticed that the panel
used to be controlled by a fully automated system which uses a PLC and a HMI. But the current operation
of the system doesn’t need an automated system. The operator was controlling the system 100%
manually. So I was to create a replacement panel with exactly the same operation.
Figure 32 - Previously Installed system

27
Figure34-Proposedpanellayout,Enclosure

28
Figure35-Proposedpanellayout,Cableductplacement

29
Figure36-ProposedpanelLayout,Componentplacement

30
Figure37-proposedpanel,MainMCCB

31
Figure38-Proposedpanel,0.5KWMotorwiring

32
Figure39-Proposedpanel,4KWmotorwiring

33
Figure40-Proposedpanel,Airblowermotor

34
Figure41-Proposedpanel,Requiredcomponentlist

35
2.3.2 Arduino Alarm clock project
I was detailed to design an alarm clock with capabilities of
 Adjusting the time with push buttons in case of a battery failure.
 Adding multiple fixed alarm times.
 Outputting alarm tone and triggering a relay.
 Operating at 12V voltage.
 Displaying the current time in 24H format in a seven segment display.
I used Arduino Nano microcontroller, RTC module based on DS1307 and 4 digit 7segment display to
create this project. I assembled the components together and developed a prototype and codded it with
using Arduino IDE. After fixing all the bugs in the program I designed a PCB for the Alarm Clock and
manufactured it using toner transfer method.
Since the PCB design needed to be smaller in size, I had to make 2 PCBs, one to solder the seven segment
display and one for the microcontroller and the power circuit. Both PCBs would mount on top of each
other and both will be connected by a ribbon.
Figure 42 - Designed prototype board

36
Figure 43 - PCB Designed by Eagle 9.0.1
Figure 45 - PCB toner transferred clad board
Figure 44 - PCB after etching

37
.
2.3.3 200I Coaxial Emulsifying Mixer drawing
In the training period I was detailed with studying the wiring diagram of an Emulsifying mixer and create
a wiring diagram. The mixer was being transferred to an another facility. So in order for their technicians
to better understand the panel, a wiring diagram was required. So after following the wiring paths and
referring to the VFD manuals I was able to make a wiring diagram for the panel.
Figure 47 - PCB after cleaning, drilling and soldering Figure 47 - PCB 2 boards mounted on each other
Figure 48 - Emulsifying mixer panel wile inspecting the wiring

38
Figure 49 - Emulsifying mixer panel dialers and controls
Figure 50 - Coaxial Emulsifying Mixer designed panel

39
Figure 51 - Coaxial Emulsifying Mixer designed panel wiring diagram

40
Figure 52 - Coaxial Emulsifying Mixer designed panel wiring

41
Chapter 03
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
 Auto Coating Machine Electrical panel replacement project.
 Alarm Clock project
 200I Coaxial Emulsifying Mixer drawing.
 Box Board packeting machine drawing.
 Tray Feeder conveyor automation project.
In order to successfully complete these projects, I had to get familiarize with Electrical symbols,
Electrical drives and I had to learn Designing and programming software such as,
 AutoCAD 2017
 Eagle 9.0.1
 RsLogix 500
 RsLogix 5000
 XCP Pro
 MR Configurator2
 Connected Component Workbench by Rockwell Automation.

42
Beside these thing I learnt a great deal about Electronics, Electrical switchgears, tools, etc.
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

43
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] (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
 [5] https://www.automation.com/

44
Abbreviations
A
Auto Coating Machine
This equipment is design to create a uniform coating of tablet with an organic solvent............. 25, 42
automate
convert (a process or facility) to be operated by largely automatic equipment. ................................ 20
B
Baud rate
Baud rate is also known as “Communication speed”......................................................................... 22
C
Connected Component Workbench
programming software for one of the newer PLC product lines called the Allen Bradly Micro800
controllers by Rockwell automation. ............................................................................................. 42
D
DSP
Digital signal processing .................................................................................................................... 23
E
eddy currents
loops of electrical current induced within conductors by a changing magnetic field in the conductor
according to Faraday's law of induction. Eddy currents flow in closed loops within conductors, in
planes perpendicular to the magnetic field..................................................................................... 17
Ethernet
Ethernet is a family of computer networking technologies commonly used in local area networks. 21
excitation
External power supply........................................................................................................................ 16
F
ferrous
containing iron.................................................................................................................................... 17
G
granulate
Grains or particles. ............................................................................................................................. 17
H
HMI
Human Machine Interface.................................................................................................................. 25

45
I
IDE
Software application that provides comprehensive facilities to computer programmers for software
development. .................................................................................................................................. 35
IGBT
An insulated-gate bipolar transistor (IGBT) is a three-terminal power semiconductor device
primarily used as an electronic switch which, as it was developed, came to combine high
efficiency and fast switching.......................................................................................................... 23
M
MOSFET
Metal Oxide Semiconductor Field Effect Transistor. ........................................................................ 23
N
nodes.
redistribution point or a communication endpoint ............................................................................. 22
P
PACs
programmable automation controllers ............................................................................................... 14
PC
Personal Computers............................................................................................................................ 14
photodiode
A photodiode is a semiconductor device that converts light into an electrical current...................... 18
phototransistor
The phototransistor is a semiconductor device that is able to sense light levels and alter the current
flowing between emitter and collector according to the level of light it receives ......................... 18
PLCs
Programmable Logic Controller......................................................................................................... 14
R
rotating magnetic field
Magnetic field that has moving polarities in which its opposite poles rotate about a central point or
axis. ................................................................................................................................................ 23
RTC
Real time clock................................................................................................................................... 35
RTD
Resistance Temperature Detector....................................................................................................... 17
S
Structured Query Language

46
Structured Query Language (SQL) is a standard computer language for relational database
management and data manipulation. SQL is used to query, insert, update and modify data......... 21
synchronization
the operation or activity of two or more things at the same time or rate. .......................................... 15
U
Ultrasonic
Vibrations of frequencies greater than the upper limit of the audible range for humans—that is,
greater than about 20 kilohertz....................................................................................................... 18

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