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Internship report on Belayab cable manufacturing PLC 2019
Declaration
We have written this report according to internship report outline given by Dilla University School of
Electrical and Computer Engineering. We declare that this work as the product of our own effort.
Student’s name signature date
Lidet Workalemahu …………… ………....
Temesgen Sime …………… ………....
Kidist Feyisa …………… …….........
Adisu Zinabu ..................... .................
This is to declare that the above statement made by the candidates is correct and true to the best of our
work.
Approval
This is to certify that the internship report declared above by students has been read and approved as their
own work and the report is written according to the outline given by university.
------------------------- ---------------- -----------------
Mentors name Signature Date
------------------------ ---------------- ------------------
Supervisor name Signature Date
SCHOOL OF ELECTRICAL AND COMPUTER ENGEENRING (SOECE) 2019 I

Acknowledgement
First of all we would like to express our heart full gratitude for our GOD to help us during our work
throughout all things. Next, we highly grateful to our internship hosting company Belayab cable. We would
also like to thank Mr. Merachew the technical manager of company and Mr. Zelalem assistant technical
manager for their advice and motivation on finding some problem or project ideas in the factory and solving
that problem. Next, we need to heartily thank Mr. Desalegn and Mr. Dawit supervisor of electrical and
mechanical department for their great support and advice and also suggestion on our daily activity. Next,
we need to thank Mr. Yemane, Mr. Alemayehu and Mr. Fetene technicians. Also, Mr. Wosen, Mr. Menur,
Mr. Abdi, and Mr. Ashenafi mechanics of company for their support. Last but not least, we need to greatly
thank Belayab cable factory employers for their support in all case that we ask them regarding to our work.
This is to declare that the above statement made by the candidate is correct and true to the best of our work.
SCHOOL OF ELECTRICAL AND COMPUTER ENGEENRING (SOECE) 2019 II

Executive Summary
This report is mainly concerning the work that we have done during our internship program. We have been
written this report to express our duration in Belayab cable factory. This report is going to be submitted
to Dilla University College of technology; school of Electrical and Computer engineering. Firstly, from
beginning up to end of this report we tried to put the overview of the company background history, main
product, raw materials and work flow of the company. In addition, this report includes about some of
machines used in the company. And also during our overall internship stay, we have acquired experiences
and accomplished tasks that help us to relate theoretical knowledge with real world technologies. Finally
the paper has benefits and skills that we have gained conclusion and our recommendation to the company
and University
SCHOOL OF ELECTRICAL AND COMPUTER ENGEENRING (SOECE) 2019 III

Table of Contents
Declaration ................................................................................................................................................................... i
Executive Summary .................................................................................................................................................... iii
CHAPTER ONE .............................................................................................................................................................. 1
1 INTRODUCTION....................................................................................................................................................... 1
1.1 Historical background of Belayab cable factory ................................................................................................ 1
1.1.1 Vision statement......................................................................................................................................... 2
1.1.2 Mission statement ...................................................................................................................................... 2
1.2 Main product and services of the company ...................................................................................................... 2
1.2.1 Block diagram of copper production system ............................................................................................. 2
1.2.2 Block diagram of aluminum production system ........................................................................................ 3
1.3 main customer of the company ........................................................................................................................ 5
1.4 work flow ........................................................................................................................................................... 6
Chapter two ................................................................................................................................................................. 8
2. The overall internship experience ........................................................................................................................... 8
2.1 How we get into the company?......................................................................................................................... 8
2.2 The section of the company we have worked in ............................................................................................... 8
2.2.1 Metal section .............................................................................................................................................. 8
2.2.2 Low voltage section .................................................................................................................................. 17
2.2.3 Quality section .......................................................................................................................................... 25
2.2.4 Maintenance section ................................................................................................................................ 28
2.3 procedures used for cable production ............................................................................................................ 28
2.4 How good we have been performing our work tasks ..................................................................................... 28
2.5 Challenges we faced during our practice ........................................................................................................ 28
2.6 Measures we have taken overcome challenges .............................................................................................. 29
Chapter three ............................................................................................................................................................ 30
3. Overall benefit we have gained during the internship .......................................................................................... 30
3.1 Improving practical skill ................................................................................................................................... 30
3.2 Theoretical knowledge .................................................................................................................................... 30
3.3 ABNORMAL VOLTAGE PROTECTION SYSTEM FOR INDUCTION MOTOR ......................................................... 30
SCHOOL OF ELECTRICAL AND COMPUTER ENGEENRING (SOECE) 2019 IV

3.3.1 Problem statement ................................................................................................................................... 30
3.3.2 OBJECTIVE ................................................................................................................................................. 31
3.3.3 Block diagram of Abnormal Voltage Protection for Induction Motor ...................................................... 31
3.3.4Software design of our project .................................................................................................................. 32
3.3.4 Interpersonal communication skills.......................................................................................................... 33
3.3.5 Team work skill ......................................................................................................................................... 34
3.3.5 Entrepreneurship skills ............................................................................................................................. 34
3.3.6 Work ethics issues .................................................................................................................................... 34
Chapter four .............................................................................................................................................................. 35
4. Conclusion and Recommendation ......................................................................................................................... 35
4.1Conclusion ........................................................................................................................................................ 35
4.2 Recommendation ............................................................................................................................................ 36
4.2.1 Recommendation to the company ........................................................................................................... 36
4.2.2 Recommendation to Dilla University ........................................................................................................ 37
Reference............................................................................................................................................................... 38
Appendix ................................................................................................................................................................ 39
SCHOOL OF ELECTRICAL AND COMPUTER ENGEENRING (SOECE) 2019 V

List of Figure
Figure 1.1: wires with black and red colors packed with 100………………………...………….4
Figure 1.2: represents cables…………………………………….……………………….……....4
Figure 1.3: represents company’s overall work flow………..…………………..………….........6
Figure 1.4: cable and wire manufacturing process.………………………………...……..……...7
Figure 2.1: drawing process ……………………………………………………………..……….12
Figure 2.2: drawing machine block diagram ………………………………………………...…….13
Figure 2.3: stranding process ……………………………………………………………..…….15
Figure 2.4: Rigid stranded machine ……………………………………………………..………16
Figure 2.5: Extrusion process …………………………………………………………..……….19
Figure 2.6: insulation machine block diagram ………………….………………………….......19
Figure 2.7: assembly machine block diagram ……………………………………….……..……22
Figure 2.8: assembler 1600………………………………….…………………………...……..23
Figure 2.9: assembly 2600 machine ………………………………………………………….…24
Figure 2.10: armoring process ………………………………………………………….….…...24
Figure 2.11: cable production procedures.……………………………….……………….…...28
Figure 3.1: block diagram of AVPIM………………………………………...……….………..31
Figure 3.2: software design of our project.…………………..…………………………………32
Figure 3.3: Output for Normal Voltage …………………………………………………………..32
Figure 3.4: Output for Over Voltage Protection System …………………………………………..33
SCHOOL OF ELECTRICAL AND COMPUTER ENGEENRING (SOECE) 2019 VI

List of table
Table1.1: Available cable size in Belayab cable factory……………………………....................4
Table1.2: Available wires in Belayab cable factory ………………………………………….…..5
Table2.1: properties of raw material used in the factory …………………………………........11
Table2.2: comparison between copper and aluminum conductor cable …………………….....11
Table2.3: types of drawing machine …………………………………………………………..….14
Table2.4: number of wires and their factor ……………………………......................................15
Table2.5: comparison of insulation material ……………………………....................................18
Table2.6: extrusion 120mm super Mac ………………………………………………..…..................................21
Table2.7: extrusion 150mm super Mac ……………………………………....................................22
SCHOOL OF ELECTRICAL AND COMPUTER ENGEENRING (SOECE) 2019 VII

CHAPTER ONE
1 INTRODUCTION
1.1 Historical background of Belayab cable factory

Belayab cable manufacturing PLC is organized by four persons with 206 million birr capital in
2008G.C. In Adama town in east direction about 4km from bus stage. There are two production rooms;
aluminum and cooper.
Cable is the main product of belayab cable factory. The common row materials for the factory is Copper,
Aluminum, XLPE and PVC. It produces different size and form of cable that are used for different purpose
based on the command of customers’ interest. The products can be used for overhead transmission line,
underground cable, home installation and etc. It uses different machines to draw cables into different size
and forms. Drawing machines to draw copper or aluminum into desired sizes; stranding machines to
twist the drawn copper or aluminum together without insulation; twisting machines to twist the strand of
copper together with small size than stranding machines, this also not insulated ; Extrusion machines to
insulate the cables with their respective sizes, assembly machines to twist the insulated copper together to
form multiple stranded, packing machines to pack the insulated copper wires by 100 meters, compressors
to supply air into the factory, water and oil pumping machines, cranes, cooling towers to recycle the
water and oils to the factory by cooling them down, rewinding machines, welding machines, bunching
machines and wood working machines to produce drums. There were different activities that we have
observed and faced different challenges in the internship period from day to day. Although, Belayab cable
factory is one of the leading cable factory in Ethiopia.
SCHOOL OF ELECTRICAL AND COMPUTER ENGEENRING (SOECE) 2019 1

1.1.1 Vision statement
To be a best choice in manufacturing of copper and aluminum electrical cables data cables in east Africa.
1.1.2 Mission statement

Manufacturing copper (cu), all aluminum alloy conductor (AAAC), aluminum steel reinforced (ACSR)
insulated and bar conductors by using genuine inputs, up to date manufacturing technologies and
qualified man power to satisfy customer requirement
1.2 Main product and services of the company

1.2.1 Block diagram of copper production system
Row material
Copper 8mm in
diameter
Large 3mm Medium Small

drawing drawing drawing
machine machine machine
Extrusion
machine Stranding
machine
Assembly
machine Extrusion
machine
Extrusion Packing
machine machine
Quality
Sheathing & test
Bering

1.2.2 Block diagram of aluminum production system
Row material aluminum

9mm in millimeter
Drawing machine
Quality test
Stranding machine
Rewinding machine
The main product of Belayab cable factory is cables and wires which are used for transmitting electrical
power in power grid transmission, and also for installation. The company uses Copper wires and Aluminum
wire with diameters of 8mm and 9 mm respectively as raw materials and draws it then strand in to different
size as required. PVC and XLPE used as row material for insulation purpose. There is wastage of PVC and
XLPE in some causes during production. The wasted PVC during production can be reused. But, XLPE is
not reused since it is rigid. So, most of the time PVC can be used in the company.

Figure 1.1: wires with black and red colors packed with 100
Figure1.2: represents Cables
It produces cables and wires with different sizes as shown in table below.
Table1.1: Available cable size in Belayab cable factory
Cable size in mm² Quantity General form

1.5 mm² 2 2x1.5 mm²
1.5 mm² 3 3x1.5 mm²
1.5 mm² 4 4x1.5 mm²
1.5 mm² 5 5x1.5 mm²
2.5 mm² 2 2x2.5 mm²
2.5 mm² 3 3x2.5 mm²
2.5 mm² 4 4x2.5 mm²
2.5 mm² 5 5x2.5 mm²

4 mm² 3 3x4 mm²
4 mm² 4 4x4 mm²
4 mm² 5 5x4 mm²
6 mm² 3 3x6 mm²
6 mm² 4 4x6 mm²
6 mm² 5 5x6 mm²
10 mm² 2 2x10 mm²
10 mm² 3 3x10 mm²
10 mm² 4 4x10 mm²
10 mm² 5 5x10 mm²
16 mm² 3 3x16 mm²
16 mm² 4 4x16 mm²
16 mm² 5 5x16 mm²
25 mm² 4 3x25 mm²+16 mm²
25 mm² 5 4x25 mm²+16 mm²
25 mm² 5 5x25 mm²
35 mm² 4 3x35 mm²+16 mm²
35 mm² 4 4x35 mm²
50 mm² 4 3x50 mm²+25 mm²
70 mm² 4 3x70 mm²+35 mm²
95 mm² 4 3x95 mm²+50 mm²
120 mm² 4 3x120 mm²+70 mm²
150 mm² 4 3x150 mm²+90 mm²
185 mm² 4 3x185 mm²+120 mm²
240 mm² 4 3x240 mm²+120 mm²
300 mm² 4 3x300 mm²+150 mm²
Table 1.2: Available wires in Belayab cable factory
Wire size in mm²

2x0.75 mm²(twins)
1.5 mm²
2.5 mm²
4 mm²
6 mm²
1.3 main customer of the company

The customers of Belayab cable factory includes:
 ELPA
 Contractors
 Real states

 Building owner
1.4 work flow

The company’s overall work flow is shown below in simplified way by using flow chart
RECEIVING
1 PRODUCTION
ORDER
COPPER, INSULATION,
2 BEDDING AND SHEATH
MATERIAL REQUISITION
IS THE
3 RAW MATERIAL
AVAILABLE? NO
YES
MATERIAL
4
MIXING
(OPTIONAL)
5
MACHINE
SET-UP
MANUFACTURING
PROCESS
6 Copper drawing and
annealing process, Stranding/
Bunching process, Insulation
process, Metering process
IS THE PRODUCT
7 AS PER THE
REQUIREMENT? NO
YES
8
COLLECTION
OF FINISHED
PRODUCTS
PACKING AND
9
LABELING
RECORDING OF
10
VOUCHER DATA
11 DELIVERY OF
PRODUCTS
Figure 1.3: Represents Company’s overall work flow

ELECTRIC WIRE AND CABLE MANUFACTURING PROCESS
TEST ON COPPER
COPPER ROD WIRE ROD
PASSED
COPPER
FOR DRAWN AND ANNEALED

DRAWING AND
ANNEALING
COPPER WIRE
FAILED
TEST ON WIRE
PASSED
PASSED CONDUCTOR
STRANDING/
BUNCHING
FAILED
TEST ON STRANDED
CONDUCTOR
PASSED
PASSED
TEST ON PVC EXTRUSION OF
COMPOUND/XLPE PVC/XLPE
INSULATION
FAILED
TEST ON PVC
PASSED INSULATION
PASSED
ASSEMBLY/LAYING
UP OF CORES (MULTI
CORE CABLES)
FOR SINGLE CORE CABLES
FAILED
TEST ON
ASSEMBLY
PASSED
PASSED EXTRUSION OF
TEST ON PVC
BEDDING/SHEATH
COMPOUND
PVC COMPOUND
TEST OF FAILED
FINISHED
CABLES
PASSED
COILING AND
PACKING
FAILED
TEST ON COILING
AND PACKAGING
PASSED
DELIVERY OF
PRODUCTS
Figure1:4: Cable and wire manufacturing process

Chapter two
2. The overall internship experience
2.1 How we get into the company?

As the curriculum stated, Dilla University sends its senior class students to different industries for the
internship program in order to interrelate real world with theoretical knowledge that the student learned
during his/her stay in the University. The internship program has positive effect for both the internship
hosting company and students. At the ending of our fourth year first semester program Dilla University
gives us the request sheet for the internship program and we tried to exhibit the internship request paper to
different organizations. We have got the acceptance paper from belayab cable manufacturing PLC. Then
November 2, 2017 was our first day to start our internship program. Something that we firmly we need to
express is that we have grasped an advanced knowledge during our stay in Belayab cable factory.
2.2 The section of the company we have worked in

There are five sections in the company and all section has its own process. These sections are metal, low
voltage, quality control, maintenance and drum production. But we were performing our tasks in only first
four sections.
2.2.1 Metal section

This section is a place where the manufacturing of cable in the factory starts. Generally there are two main
processes carried out in the metal section of the factory.
1. Drawing section: the area at which drawing process take place
2. Stranding section: the area at which stranding process carried out

There are two types of metals used as a raw material in cables manufacturing:
 Copper /Cu/ with Diameter 8mm and weight (3-4) ton
 Aluminum /Al/ with Diameter 9mm and weight 1.5 ton

Copper Rod
Application: Copper rod specified by the following standard is mainly used for electric cables; were
conductors drawn as soft or hard. This rod is drawn to minimum size of 0.2mm diameter.

Standards: The latest edition of the following standard is applicable.
 BS EN 13601
 ASTM B49
 BS EN 1977
Requirements:
 Size: copper rod shall be of round cross sectional area of 8mm diameter with ±0.38mm as tolerance.
 Electrical properties:
 Minimum conductivity of 101% IACS
 Maximum electric resistivity shall not exceed 17.07 ohm.mm2/km at 200c
 Mass resistivity shall not exceed 0.15176ohm.g/m2 at 200c i.e. density shall not exceed
8.89G/mm2/M at 200c
 Mechanical properties:
 Minimum tensile strength is 200N/mm2
 Minimum elongation 35%(in 250mm)
 Chemical properties:
 Surface oxide to be less than 400Å
 Finishing and appearance: Copper rod should be supplied in form of rose coiler coils in one
continuous length without any kind of joints. Rod should be clean, smooth and free from pipes,
twists seems, damage ends, excessive oil and other injuries.
 Packing and marking: The copper rod coil should be of maximum diameter of 2.0m and of
maximum height 1.0m. Each coil weight should not exceed 4.5MT and not less than 3MT.
Acceptance test: The following tests and checks are conducted as acceptance test.
 Appearance checks
 Diameter measurements

 Electrical properties
 Mechanical properties
 Density
 Surface oxide
 Chemical composition analysis(first time supply)

Aluminum Rod
Application: Aluminum rod is mainly used for the underground and overhead cable conductors. This rod
is drawn to minimum size of 1.05mm diameter.
Standards: The latest edition of the ASTM B233 standard is applicable
Requirements:
 Size: Aluminum rod shall be of round CSA of 9.0mm diameter with ±0.3mm as tolerance or 9.5mm
diameter of with ±0.5mm as tolerance.
 Electrical properties:
 Minimum conductivity of 61.5% IACS
 Maximum electrical resistivity shall not exceed 28.035ohm.mm2/km at 20oc.
 Mechanical properties: Tensile strength should range from 8.5 up to 11.9 kg/mm2
 Finishing and appearance: Aluminum rod should be supplied in form of coils in one continuous
length without any kinds of joints. Rod should be clean, smooth and free from excessive oil,
damaged ends and other defects.
 Packing and marking: The Aluminum rod coil should be of maximum diameter of 1.5m and of
maximum height 1.0m. Each coil weight should not exceed 2.3 ton and not less than 1.8 ton.
Acceptance Test: The following tests and checks are conducted as acceptance test:
 Appearance checks
 Diameter measurements
 Electrical properties

 Mechanical properties
 Density
Raw Diameter Elec. Tensile Elongation Weight
material (mm2) Resistivity(Ω. Strength(Kg/ (g/mm2/m)
m2/Km) mm2)
AL.H12 9 28.264 8 : 10.5 20% 2.7
AL.H14 9 28.264 10.5:14 15% 2.7
Copper 8 17.241 Max. 250 40% 8.89
Table 2.1 properties of raw material used in the factory
Notes:
 The max. Tensile strength of the copper means the maximum force that can apply over cross section
area.
 Low efficiency of conductor when Elongation and Cross sectional area increasing because the
resistance will increase too.
Copper /Cu/ Aluminum /Al/
Low specific resistance About 40% higher specific resistance
Good conductor of electricity with small Good conductor of electricity with large
CSA CSA
Heavy in weight Light in weight

More expensive Cheaper than copper
Best for cables required for high stresses Best for cables required for flexibility
Mainly used for underground cables Mainly used for underground cables
Table 2.2 comparison between copper and aluminum conductor cable
Drawing process
Drawing is a mechanical deformation process carried out as the metal is below its re-crystallization
temperature, to reduce the wire diameter by tension force. This has two main functions:
I. It gives the required shape to the metals
ii. It improves the mechanical properties of metals by refining the structure

Here in the drawing section, between 17 and 33% of the initial diameter can be reduced by passing the wire
through a series of dies with certain sequence till we get the required diameter.
Figure 2.1: drawing process

Calculation of reduction ratio or Elongation;
From conservation of mass theory the mass of cable before and after drawing is constant therefore;
Mass1 = Mass2
ρ.L1.A1= ρ.L2.A2
L1.π/4.D1=L2.π/4.D2
L2=L1+ΔL
L1D1= (L1+ ΔL).D2
D1/ D2= (L1+ ΔL)/ L1=1+Σ%
Σ%= D1/ D2 - 1
Where
Σ-Reduction ratio or Elongation
D1-Diameter of wire before reduction process
D2-Diameter of wire after reduction process
From the final equation if the reduction ratio is known; one can calculate the die size of all stages.
Main component of drawing machine
 Pay off
 Drawing block
 Final capstan block

 Annealing machine
 Dancer
 Take up
Final capstan block Annealing machine
Pay off Drawing block
Take up Dancer
Figure 2.2: drawing machine block diagram

1. Payoff: It is the first stage in the drawing process; its function is to take row material to the second stage.
2. Drawing block: It is the main part of machine where the drawing process takes place; the function of
this machine is to reduce the diameter of conductor through a series of dies.
3. Final Capstan Block: The function of the last capstan is to be sure that the diameter of wire not changed,
to reduce the cut of wire and the number of turns in technical recommendation catalog.
4. Annealing Machine: Since the drawing process done is cold working drawing operation, the grain
structure changes. The deformation takes place when the applied stress exceed the elastic limit during cold
pressure when severe stresses known as residual stresses are developed in the metal. This stresses can be
removed by suitable heat treatment known as annealing. Annealer exists only in copper wire drawing
process. This operation is temperature process for copper metal after drawing operation done by increasing
the heat to 50 degree; but isolating system from air to decrease the hardness and retain material properties
of copper again because its property is changed in the drawing process.
5. Dancer: it is constructed from two capstans, pneumatic system, and its function is to make
synchronization speed between take up and the feed speed of drawing block.
6. Take up: It is a basket or bobbin that is used to hold coils.

Types of Drawing Machines
There are basically two types of drawing machine used in the factory.

a) Heavy drawing machine
 Copper drawing machine
 Aluminum drawing machine
b) Intermediate drawing machine for flexible copper

Kinds of machine
Items Intermediate Heavy drawing Heavy drawing machine aluminum
drawing machine copper
machine
Max. No of dies 14 13 15
Min. diameter(mm) 0.26 1.2 Inlet diameter Outlet diameter
9.5 9
1.7 1.53
Max. diameter(mm) 1.35 4.5 Inlet diameter Outlet diameter
9.5 9
4.5 5.2
Max. speed(m/s) 30.05 31.5 37.5

37.5
Table 2.3 types of drawing machine
Stranding process
The need of making the stranding operation is that:
 The current flows typically along the surface of the conductor (skin effect).so, to allow the
conductor to carry more current; more wires of smaller cross-sectional areas are used instead of

using just one of larger area. In this way, conductors are made of layers of wires. The conductor of
cables consists of a number of strands of wire of circular cross section so that it may become flexible
and carry more current.
 To avoid the bending and deformation of the conductor under normal conditions.
The numbers of wires in stranded cables are: 7,19,37,61,127 and 169.
Figure 2.3: stranding process
Lay length: It is the distance (in mm) between two consecutive ups or downs of a certain component of
the cable. Lay length = ϕ final conductor x Factor
Conductor Factor
91 8-10
61 10-12
37 12-14
19 14-16
7 16-18
Table 2.4 number of wires and their factor
Calculation method of circular conductor diameter is by this equation;

Dc = μ.Dw

Where; Dc- the diameter of conductor of the cable
Dw- the diameter of the wire, μ- Lay factor
Stranding Cables
A. Sector cable (used for low voltage range of 3 X 120 – 4 X 90 – 3 X 100 + 60)
B. Round cables
C. Compact round
Classification of stranding machines
Figure 2.4: Rigid stranded machine

1. Rigid stranding machine: This machine has a capacity of stranding up 61 wires but in this
Factory it can strand a maximum of 37 wires.
The machine consists of:
Feeding carrier.
 Rotating cage contains 6 pulley carriers.
 Rotating cage contains 24 pulley carriers
 Double capstan of diameter 2m.
 Receiving carrier. Figure 2.4 Rigid stranded machine
 Rollers after each cage used in compact and sector conductor.

2. Double twist machine.
This machine strands the wires by using a rotating arm which rotates fast twisting the wires, and then the
wires are reversed to be turned on the receiving pulley which rotates around itself and that is the other
twist.
3. Tubular stranding machine
It is seven wire, both copper and aluminum, stranding machine used to strand wires of small size.
4. Bunchier stranding machine
This is machine is used to strand flexible wires drawn by intermediate drawing machine. It can stand up
to 14 wires bobbins as pay off.
2.2.2 Low voltage section

There are five process made in this section
1. Insulation
2. Assembly
3. Bedding
4. Armouring
5. Sheathing
Insulation
There are two types of materials used for insulation in this factory
1. Thermoplastic material: type of material that can be recycled such as Polyvinyl chloride (PVC)
2. Thermosetting material: type of material that cannot be recycled such as XLPE

The XLPE material consists of PE (polyethylene); with Catalyst material and by operating condition it is
converted to XLPE such that PE + Catalyst → XLPE
PVC XLPE
Cost Cheaper than XLPE More expensive than
PVC
Recycling Yes No
Operating temp. 70°C 90°C

Density From 1.4 to 1.6 g/cm3 0.92g/cm3
Table2.5 comparison of insulation material

Both PVC and XLPE are used as insulation for low voltage cable, while XLPE is also used just for MV
and HV cable. However, the material property of XLPE used in MV and HV is more pure than in low
voltage so it is stronger and more expensive. PVC and XLPE are colorless by nature. Cables are colored
according to the customer needs and the standards. The basic colors are: red, yellow, blue, and black. The
ratio of color is 2% for PVC and between 0.5% to 1% for XLPE. The material used for coloring is called
“master batch”.
Properties of cable insulation
 Must have specific resistance.
 Must be high dielectric strength (KV/mm)
 Rigid and flexible.
 Must be non-flammable.
Extrusion Process
Insulation of conductor cable process is carried out in this section. It has two main functions;
 To protect the cable from any behind air
 Insulate the conductor from any other conductor
This section is the most important part of the overall production section. Before starting the extrusion
process great care must be taken on the following part:
 The quality product should be checked at every stage
 The dimension should be standardized
 Cooling system must be checked

Figure 2.5: Extrusion process
Pay off Caterpillar Extruder Cooling Spark tester

trough
Take up Caterpillar
Figure 2.6: insulation machine block diagram

1- Pay off: feed the machine with conductor.
2- Caterpillar: to pull the conductor. There are two caterpillars one at the beginning the machine and other
at the end; the speed of two caterpillars must be synchronized.
3- Extruder: consists of screw, barrel and crosshead. The screw part consists of five zones which used to
heat the insulation material PVC or XLPE before going to the crosshead of the machine; the head part
consists of four heaters
4- Cooling trough: necessary to cool it before going into the reel.
5- Spark Tester: apart that response of the test insulation. Its idea is that applied DC voltage reached to 10
KV to test the insulation of the wire.
6- Take up is the reel that is ready to go to the assembly process.

Extrusion machine used

i. Extruder 80mm
 Processes made : Insulation
 Diameter of the cable from 0.5 mm2 to 10 mm2
 Materials used in this machine : PVC and XLPE
The next conductors are insulated with this machine: stranded, flexible and solid.
 Max. line speed 1000 m/min
 Spark detector is installed to verify that the insulation has no faults.
 Pay off and Take up: two units with reel of maximum diameter of 1000 mm and minimum diameter
of 630 mm and maximum weight of 1 Ton.
 This machine has no caterpillars instead it is using two capstans to apply tension to the conductor
and make the insulation attached to conductor.
ii Extruder 120mm super Mac
 Pay off and take up of two units with bobbin size of max. Diameter of 2250mm and min. diameter
of 800mm and max. Weight of 6 ton.
 This machine has two caterpillars.
 Processes made : Insulation, bedding and sheathing
 Diameter of the cable: copper or aluminum conductors from 5 mm2 (round) to 57 mm2 (sector or
round).
 Materials used in this machine : PVC and XLPE
 Spark detector is installed to verify that the insulation has no faults.
Extruder 120mm
Screw 1 Screw 1

Length/diameter ratio(L/D) 25 25
Maximum rpm 80 rpm 100 rpm
Maximum output PVC 600 Kg/Hr. 120 Kg/Hr.
Number of heating zone 6 zones 4 zones
Table 2.6 extrusion 120mm super Mac

iii. Extrusion 150mm super Mac
 Pay off and take up of one unit with Bobbin size of max diameter of 3600mm, min diameter
1100mm, and max weight of 20 ton.
 Processes made : Insulation, bedding and sheathing
 Diameter of the cable: copper or aluminium conductors from 11 mm2 (round) to 115 mm2 (sector
or round).
 Materials used in this machine: PVC and XLPE, low smoke material ……etc.
 Spark detector is installed to verify that the insulation has no faults
Screw 1 Screw 2
Screw diameter 150mm 600mm

Length/diameter 25
ratio(L/D) 25
Maximum rpm 60 rpm 100 rpm

Maximum output 900 Kg/hr. Kg/hr.
Number of heating 6 zones 4 zones

zone
Breaker plate Filter

Table 2.7 extrusion 150mm super Mac
Assembly process
The main function of this stage to assemble all phases and neutral together; and covers them with propylene
tape. During this first step all conductors are assembled together in one cable and after that the cable is
covered with polypropylene tape.
Pay off Assembly Correct angle Dies stage

Block
Take up Tape or
Figure 2.7: assembly machine block diagram armouring
stage

Assembly machines
a. Assembly 1600
b. Assembly 2600
a. Assembly 1600
It is used just for assembling and armouring (steel wire). In the assembly operation, this machine is used
just with round conductors with small sizes, basically control cables, and made up to 24 phases.
Figure 2.8: assembler 1600

b. Assembly 2600
This machine is used with all kind of process: Assembly armouring (steel wire armouring SWA or steel
tape armouring STA) and screening.

Figure 2.9: assembly 2600 machine

2.3.4 Armouring process
The armouring stage is carried out to protect the cable against any mechanical stresses, for instance, ground
pressure appeared over the underground cable when a big truck is passing over generating a pressure force
through the soil that may reach the cable.
When the cable is working under normal conditions, the current flowing through the conductors generates
a magnetic field which produces current circulating along the layer of armouring; therefore it needs to be
grounded in some point.
Figure 2.10: armouring process

Types of Armoring
1. Steel tape armouring: This type of armouring is carried out basically to protect the cable against any
horizontal mechanical stresses as explained before. Apart from that, it can also carry the earthlings fault

current. This type of armouring is done with two steel tapes by using an over gap process: The second layer
of tape is placed over the first one by 50 % over gap of the tape width, the size of the tape is specified by
its width and thickness by this equation i.e. Tape width x Tape thickness
2. Steel wire armouring (galvanized): This type of armouring is carried out to protect the cable against
strains: the horizontal tensions appeared along the cable. The wires can also carry the earthling fault current.
The operation is carried out by covering all the surface area of the cable with wire called "Armouring Lay"
.one period of wire moving around the cable can be determined as Armouring lay = factor X diameter of
the cable.
Bedding
This process is done right after the assembly process. It is an operation done between stages, before
armouring, and before sheathing.
Sheathing
The sheath is the cover of a cable just used for mechanical protection. This process uses the same extrusion
method as that one used for insulation and bedding. PVC is used as sheathing material.
Coiling process
Single core cables, insulated by Ex-80 extrusion machine and of size 1.5-2.5, are coiled by two coiling
machine. Cables have pay off and take up. The spool, which is produced in that company from waste of
PVC insulating material, is used as take up. Cables are coiled in length of 100m and packed by closed loop
operated packing machine. Sekora sensor is available to test insulation fault on the cable being coiled.
2.2.3 Quality section

There are four classes of quality section.
1. Quality assurance
2. Quality control
3. Electrical lab
4. Non-electrical lab
Quality assurance
Quality assurance is the process of verifying or determining whether products or services meet or exceed
customer expectations. This process considers design, development, production, and services. The most
popular tool used to determine quality assurance consists of four steps: plan, do, check, and act; abbreviated

as PDCA. It is an effective method for monitoring quality assurance because it analysis existing condition
and method used to provide the product or service customer. The goal is to ensure that excellence is inherent
in every component of the process. Quality assurance also helps determine whether the steps used to
provide the product or services are appropriate for the time and conditions. In addition, if the PDCA cycle
is repeated throughout the life time of the product or service, it helps improve internal company efficiency.
Quality control
Quality control is a process employed to ensure a certain level of quality in product or service. The basic
goal of quality control is to ensure that the products, services, or processes provided meet specific
requirements and are dependable, satisfactory, and fiscally sound. It can cover not just products, services,
and processes, but also people. Employees are an important part of any company. If a company has
employees that do not have adequate skills or training, have trouble understanding directions, or are
misinformed, quality may be severely diminished. When quality control is considered in terms of human
beings it concerns correctable issues.
In quality control section there are three sections to check the products starting from the raw material used
and during all various production process, till the final stage to ensure the quality of the products and to
confirm the required specification before it shipped to the customer.
1st stage-raw material test
All raw materials are brought into the stores and placed into the ware house for quality control to process
and test according to materials book and work instruction for each material. These are then reported as
either accepted or rejected.
2nd stage-in process test
The purpose of in process test is to maintain production standards and ensure the compliance of product
with the tolerance set out and manufacturing specification.
I. Wire drawing process: parameters that have to be checked during this process are:
 Elongation test for 10% of the drawn wires
 Tensile strength for 10% of the drawn wires
 Wire diameter for 10% of the drawn wires
 roundness for 10% of the drawn wires

II. Stranding process: parameters that have to be checked during this process are:
 Resistance measurement
 Weight measuring
III. Insulation process test: parameters that have to be checked during this process are:
 Insulation thickness
 Spark test
 Color of insulation
 Hot set test for XLPE insulation

3rd stage-final sheathing
The physical properties measured to check compliance are:
 Thickness of outer sheath
 Cable marking(embossing) or printing
 Spark test
 Color of outer sheath
 Length marking
Electrical lab
This is the final test of quality section. In this lab, physicians test the resistance of cables and its low
voltages (1kv) or its conductivity. However, the test takes place for 1kv, the company tests up to 3kv for
high quality.
Non-electrical lab
In this non-electrical lab, the test takes places are:
 Raw material test
 Type test
 Routine test

2.2.4 Maintenance section
When machine is in operation it may fail electrically and mechanically due to friction and electrical fault.
This section play a vital role in maintaining break down machines and installing new machines. Both
mechanical and electrical Engineers are available in section to maintain mechanical system and el electrical
circuits, design dies and install program on plc.
2.3 procedures used for cable production
Figure 2.11: cable production procedures
2.4 How good we have been performing our work tasks

Based up on the experience we gained day to day life from the workers in the company, we have been
doing our work best without being exhausted by keeping work ethics being punctual and also by respecting
each other during our internship period.
2.5 Challenges we faced during our practice

It was difficult to get into the company, since they denied training us for the sake of lack of place.
We couldn’t cope with machines working principle because they are installed with plc program.
The company’s engineers didn’t give us a detail explanation about machines available in company because
they were busy.

No safety materials given for me
2.6 Measures we have taken overcome challenges

We made an effort to know about machines and their working principle asking operators in the company
We tried to communicate smoothly with human resource manager to get into the company
We used safety materials by myself and participated by motivation

Chapter three
3. Overall benefit we have gained during the internship
3.1 Improving practical skill

We have been gain many knowledge:-
 We have got the knowledge about how the real work look like.
 How to supply electric power to the machine.
 How to start different type of machines.
 How to protect our self from electric power or from accident that come by a machine.
 How to control the overall electric machines.
3.2 Theoretical knowledge

For the last four year we have stayed in the University and we have grasped the theoretical knowledge.
But, now this internship programs strengthen our theoretical knowledge by practice. When we were in the
University there were some theory that we are not understand but now it became clear because we observe
it practically. The most noticeable thing that we have gained is we combine or relate theoretical knowledge
with practical skills or experience. We solve some problem that we faced in the company. We improve
project working skill by performing two project; those are oil level indicator and earthing system for all
machines. We calculate current rating of all machines in belayab cable manufacturing PLC.
3.3 ABNORMAL VOLTAGE PROTECTION SYSTEM FOR INDUCTION MOTOR

3.3.1 Problem statement
Belayab cable factory has not merely developed abnormal voltage protection system so motors, machinery
& appliances are in danger. Now we try to solve this problem. The obstacle of power fluctuation on
electrical equipment are a serious problem. The most stress in an induction motor protection is the high
cost of the motor and the use full reduce cost when induction motor and other use full equipment fails
during voltage instability. Under voltage and over voltage are the main types of voltage instability.

The exchange of power fluctuations especially in our country prompted the consumers to suffer from these
shortage which often times detrimental to the life of every power utility installation aside from the manager
of power brown-outs.
3.3.2 OBJECTIVE
3.3.2.1 General objective

The main objective of this project is to design and implement abnormal voltage protection system for
induction motor.
3.3.2.2 Specific objectives

 To protect motors from damage.
 To design the over voltage and under voltage protection system.
 To increase motors life.
 To simulate system in accordance to the established design parameters.
3.3.3 Block diagram of Abnormal Voltage Protection for Induction Motor
Figure 3.1: block diagram of AVPIM

3.3.4Software design of our project
Figure 3.2: software design of our project
The normal voltage condition
During normal voltage condition where the AC voltage supply is within the interval from 175V to245V,
the output component represented by the motor performed its normal function without any treat of damage
or possible burnout. Figure 5.2 reflects the circuit in the normal voltage condition where the relay contact
is triggered to provide current continuity to power the motor as indicated by the encircled relay.
Figure 3.3: Output for Normal Voltage

The Under Voltage and Over Voltage Control System Circuit Design
The circuit design stipulated in the methodology is utilized in the simulation of the corresponding under-
voltage and over-voltage protection parameters. Specifically, simulations for under-voltage and over-
voltage are conducted to determine the range and level of protection were observed. The output of the
entire system was checked separates.
Figure 3.4: Output for Over Voltage Protection System

3.3.4 Interpersonal communication skills
When we were in the factory, there were engineers and technicians that lecture us about the factory working
principle and about the machine etc. So, this internship program create opportunity to improve our
communication skill with the employees in the factory. Not only with employees but also with our friends
that come from different University. In addition to this if some problems happen we communicate with our
mates, technicians and engineers as a result of this our communication skill is improved due to intern ship
program.

3.3.5 Team work skill
Obviously, be with group is better than being alone. By considering this we make team with other internship
student comes from Arbaminch University. Then, we share idea on different things regarding our work in
our hosting company and about our University education relative to their University.
We also make a team with maintenance section of our hosting company to work on the technical issues in
the factory with them.
3.3.5 Entrepreneurship skills

In the factory there are problems that comes in different period of time. So, solution is must for these
problems. In the progress of finding solution for the problem new thing is invented or the machines are
modified. When we observe this, we are initiated for creativity and in addition to this there are many
entrepreneurship skills that we have developed in the company:-
 Multi skilled in the work place

 Being creative and innovative
 The risk taker for our work
3.3.6 Work ethics issues

Work ethics mainly concern about ethical work conduct and this is the common ethical rule of conduct for
the workers of all profession. An important part of work ethics is maintaining labor discipline. This means
obeying the rule and regulation of the work place. Those rule and guidelines are usually designed to
facilitate efficient working. Labor disciplines are listed below.
 Punctuality
 Proper use of instrument of work place
 Working harmoniously in cooperation with co-workers
 Being obeyed for what we have pleased.
The work discipline that we have been listed before are one of the vital thing that we have been learned
from the factory and also we have been experiencing this labor discipline in our duration.

Chapter four
4. Conclusion and Recommendation
4.1Conclusion
The Belayab cable manufacturing factory have the main plants such as drawing plant, stranding plant,
twisting plant, extrusion plant, assembling plant, packing plant, bunching plant, water and oil pumping
plant, rewinding plant, air compressor plant as common with electrical power gained either from ELPA or
generator to accomplish the cable manufacturing process. Almost all instruments and equipment that we
are used to control the factory process parameters (pressure, flow, liquid levels and speed) and the control
system strategy are almost the same for each plant. There are both analog and digital systems in Belayab
cable factory. Theoretical knowledge is the basic prerequisite for gaining the practical skill such that we
develop our practical skill in contactor, relay, pneumatic actuator, solenoid valve, induction motor,
capacitor starting capacitor running motors, gear box and belt work to transmit the power from motors to
the actual load, pressure gauge, mechanical selector switch and electrically operated switch to limit the
movement of the moving part of machines to protect them from colliding, proximity sensors, annealing
principles to make the copper wire so flexible, temperature sensors, about invertors, dies to elongate the
copper wire into the desired size, tension regulator and so on during our internship period.
During our stay in the factory we have grasped a lot of knowledge also we relate the theory that we have
learned in the University with practice and the most satisfactory advantage of internship program was
understanding the theory that we did not understand in the University, when we observe it practically. We
have got a lot of skill during the internship program but dominantly the skills that we got during the
internship program are:-
 Communication skill
 Leadership skill
 Team working skill
 Entrepreneurship skill

 Also we improve project working skill by performing two project; those are oil level indicator and
earthing system for all machines.
 We calculate current rating of all machines in belayab cable manufacturing PLC.
Generally during our stay in the company in addition to getting knowledge we know how the real
working life look likes. During our internship period we encountered some problems like:
 We couldn’t get chance to see the internal part of some device or instrument during our internship
period.
 We were guided by technician or maintenance section if and only if they had no work to do (or if
they had a free time) otherwise; we ask the operators of that plant what we have to know by
ourselves and we didn’t get an electrical engineer.
 This company haven’t manual that can prepared by English language for each machines.
4.2 Recommendation
4.2.1 Recommendation to the company
In our internship from starting day up to now, we get different knowledge. The company overall work
strategy is very good. Belayab cable factory is the best place for anyone who wants to get good
knowledge and experience and also students like us (especially engineering students) can get a good
work time experience. The company is best for they think for students in case of transportation and food.
But, the company has to put the engineer advisor for internship students. Our country needs us for
building the better Ethiopia with new technologies. Therefore, please take a good care of the youngest
generation Finally We have something to say for all skilled workers & who want to build a better
Ethiopia;
“You don’t have to be a boss, you have to be a leader” boss only give order but leader lead by example
 Most of the factory machines are analog type. It’s good if turn some of the machines into digitals
since it is more flexible, reduce the error than analog. Therefore change this analog type of machines
with the digital types of machines.
 Excess man power lead to overhead cost.

 Most of factory’s controlling system operates manually. This leads to excess man power. So to
reduce man power and to increase amount of production of products, automatic programmable logic
control (PLC) controller is recommendable.
 For those motors that their nameplate smashed or painted, it’s good to recover their nameplates
 It’s good to clean some parts of machines like motors and others to maximize their life.
4.2.2 Recommendation to Dilla University

We strongly suggest this apparent ship must carry on because it is the best thing to develop skill to the
students, also doing one time only in five years is not well and suggest it may occur more than one time.
Also this practical report is very important for students because it helps them to now the real world
environment what we face after graduation and increases their experience and skills. Student who done the
practical report, could not get any difficulty when they are going to start their final project work and easily
understand what they have to do, how to make interaction with the employee of the organization and learn
how to get the accurate information from workers of the organization, simply understand, and know their
work discipline, and what problems concurrently happen in their work discipline and get ready to solve the
problems.

Reference
1) Orally asking the company employers and leaders for some of information we need
2) The quality assurance manual by Abinet Gezmu and Biniyam Teshome that we have got from
maintenance leader
3) From the internet //www.belayabcable.com
4) William A. The. Electrical Power Cable Engineering, Third Edition

5) . Annette von Jouanne and BasudebBanerjee, “Causes and Effect of Voltage Unbalance Mitigation
Techniques”, 2001.
6) . Mohammad Shah Alamgir and Sumit Dev, “Design and Implementation of an Automatic Voltage
Regulator with a Great Precision and Proper Hysteresis”, Vol.75, year 2015, pp., “IJAST”.
7) . C.H.Vithalani, “Over-Under Voltage Protection of Electrical Appliances”, August 2003,
Electronics for You

Appendix
Short form Full name
M Meter
Mm Millimeter
kW Kilowatt
kVA Kilovolt ampere
PVC Polyvinyl chloride
XLPE Cross Linked Polyethylene
P.L.C Private limited company
ISO International standard organization
EELPA Ethiopian electric light power authority
kV Kilovolt
ꭥ/km Ohm per kilometer
Cu Copper
Al Aluminum
e.c Ethiopian calendar
HV High voltage
MT Mega Tone
MV Medium Voltage
BS British Standard
IAC International Electronics Code


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Internship report on Belayab cable manufacturing PLC 2019

Student’s name signature date

Lidet Workalemahu …………… ………....

Temesgen Sime …………… ………....

Kidist Feyisa …………… …….........

Adisu Zinabu ..................... .................

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

Mentors name Signature Date

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

Supervisor name Signature Date

SCHOOL OF ELECTRICAL AND COMPUTER ENGEENRING (SOECE) 2019 I

SCHOOL OF ELECTRICAL AND COMPUTER ENGEENRING (SOECE) 2019 II

SCHOOL OF ELECTRICAL AND COMPUTER ENGEENRING (SOECE) 2019 III

SCHOOL OF ELECTRICAL AND COMPUTER ENGEENRING (SOECE) 2019 IV

SCHOOL OF ELECTRICAL AND COMPUTER ENGEENRING (SOECE) 2019 V

SCHOOL OF ELECTRICAL AND COMPUTER ENGEENRING (SOECE) 2019 VI

Table1.2: Available wires in Belayab cable factory ………………………………………….…..5

Table2.1: properties of raw material used in the factory …………………………………........11

Table2.2: comparison between copper and aluminum conductor cable …………………….....11

Table2.3: types of drawing machine …………………………………………………………..….14

Table2.4: number of wires and their factor ……………………………......................................15

Table2.5: comparison of insulation material ……………………………....................................18

Table2.6: extrusion 120mm super Mac ………………………………………………..…..................................21

Table2.7: extrusion 150mm super Mac ……………………………………....................................22

SCHOOL OF ELECTRICAL AND COMPUTER ENGEENRING (SOECE) 2019 VII

1.1 Historical background of Belayab cable factory

SCHOOL OF ELECTRICAL AND COMPUTER ENGEENRING (SOECE) 2019 1

1.1.2 Mission statement

1.2 Main product and services of the company

Large 3mm Medium Small

SCHOOL OF ELECTRICAL AND COMPUTER ENGEENRING (SOECE) 2019 2

Row material aluminum

SCHOOL OF ELECTRICAL AND COMPUTER ENGEENRING (SOECE) 2019 3

Figure1.2: represents Cables

Table1.1: Available cable size in Belayab cable factory

Cable size in mm² Quantity General form

SCHOOL OF ELECTRICAL AND COMPUTER ENGEENRING (SOECE) 2019 4

Wire size in mm²

1.3 main customer of the company

SCHOOL OF ELECTRICAL AND COMPUTER ENGEENRING (SOECE) 2019 5

1.4 work flow

Figure 1.3: Represents Company’s overall work flow

SCHOOL OF ELECTRICAL AND COMPUTER ENGEENRING (SOECE) 2019 6

FOR DRAWN AND ANNEALED

Figure1:4: Cable and wire manufacturing process

SCHOOL OF ELECTRICAL AND COMPUTER ENGEENRING (SOECE) 2019 7

2. The overall internship experience

2.1 How we get into the company?

2.2 The section of the company we have worked in

2.2.1 Metal section

2. Stranding section: the area at which stranding process carried out

 Aluminum /Al/ with Diameter 9mm and weight 1.5 ton

SCHOOL OF ELECTRICAL AND COMPUTER ENGEENRING (SOECE) 2019 8

 Minimum conductivity of 101% IACS

 Maximum electric resistivity shall not exceed 17.07 ohm.mm2/km at 200c

 Minimum tensile strength is 200N/mm2

 Minimum elongation 35%(in 250mm)

 Surface oxide to be less than 400Å

SCHOOL OF ELECTRICAL AND COMPUTER ENGEENRING (SOECE) 2019 9

 Chemical composition analysis(first time supply)

 Minimum conductivity of 61.5% IACS

 Maximum electrical resistivity shall not exceed 28.035ohm.mm2/km at 20oc.

SCHOOL OF ELECTRICAL AND COMPUTER ENGEENRING (SOECE) 2019 10