HOME POWER MONITORING SYSTEM

ADDIS ABABA SCIENCE AND

TECHNOLOGY UNIVERSITY
Department of Electrical and Mechanical
Engineering
Department of Mechanical Engineering
Design stream
Internship report
COMPANY NAME: ETHIOPIAN AIRLINES

By:

Supervser :

Advisors:
- Elias Gebremichaeal
- Asrat Mulata

Addis Ababa
Feb, 2019

ACKNOWLEDGMENT
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First of all, I would like to tank almighty God the crater of all things. He gives a time on my life to
see and making everything. On the next I would like to express our deepest gratitude to our
project advisors for the very helpful comments they gave us. We would also like to extend our
gratefulness to all who are directly or indirectly involved in the successful completion of this
internship program.

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TABLE OF CONTENTS
CHAPTER ONE..................................................................................................................................5

1.1. Overview of Ethiopian airlines.................................................................................................5

1.1.1Historical Background..............................................................................................................5

1.1.2Vission......................................................................................................................................6

1.1.3 Mission............................................................................................................................6

1.1.4. Values and principles of Ethiopian........................................................................................7

1.1.5. Strategic Objectives.......................................................................................................7

1.1.6. Products and Services of Ethiopian Airlines..................................................................7

CHAPTER TWO:................................................................................................................................8

2.1. The internship experience........................................................................................................8

2.1.1. General Objective..............................................................................................................8

2.1.2. Beginning the internship.....................................................................................................8

2.1.3. Training.............................................................................................................................8

2.2. Overview of Inflight catering.....................................................................................................8

2.2.1. Organizational Structure .................................................................................................11

2.2.2. Basic Function of Inflight Catering facility maintenance .....................................................11

CHAPTER THREE.............................................................................................................................13

3.1. Project: Catering Cold RoomsFailureMaintenance ....................................................................13

3.1.1. Introduction........................................................................................................................13

3.1.2.Statement of the problem....................................................................................................13

3.1.3 Scope of the work.............................................................................................................13

3.1.4. Objectives........................................................................................................................13

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3.1.5Methodology.....................................................................................................................14

3.1.6Materials and tools used.................................................................................................14

Dish Washing Machine............................................................................................................14

Rotational Oven Machine...........................................................................................................15

Ice cube machine …………………………………………………………………………… 15

Asterophisics X-ray machine……………………………………………………………….. 15

3.2.Project work on cold room machinery....................................................................................16

3.3. Emergency failures and troubleshooting...............................................................................18

CHAPTER FOUR:.............................................................................................................................21

4.1. Benefit gained from the internship..........................................................................................21

CHAPTER FIVE:...............................................................................................................................22

5.1. Conclusion and Recommendations....................................................................................22

Reference..............................................................................................................................24

List of Figures

Figure 2:1 Ethiopian Inflight catering facility………………………………………….. 9

Figure 2:2 organizational structure …………………………………………………….. 11
Figure 3:1 MISA cold room outdoor unit ………………………………………………. 16
Figure 3:2 CELTIC cold room condenser unit …………………………………………. 17
Figure 3:3 before and after maintenance of dispatch holding …………………………… 19
Figure 3:4 before and after maintenance of oil separator ………………………………… 20
Figure 3:5 before and after maintenance of joint leakage………………………………… 21

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Executive Summary

This report describes the work conducted during the four-month internship program at
Ethiopian Inflight catering facility maintenance department. This internship is part of
theMechanical engineering curriculum at Addis Ababa Science and Technology University.
During this internship, briefings on historical background of Ethiopian airlines, rules and
regulations of Ethiopian airlines, the general structure of Inflight catering facility maintenance
were discussed in detail. In addition, different tasks and projects were given by respective
supervisor to help us understand and be familiarize with the equipment and working principles.
Finally, those projects and tasks have been presented to the supervisors and managers in our
respective areas. Accordingly, they gave us feedbacks and improvement points on the project.

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CHAPTER: ONE
1.1. OVERVIEW OF ETHIOPIAN AIRLINES COMPANY
1.1.1. HISTORICAL BACKGROUND
Ethiopian in the years following the end of the Italian occupation, Ethiopia was in talks
with the governments of France and Sweden to establish a commercial airline of its own. An
agreement was even signed with the Swedish government for the establishment of such an
airline under the auspices of the Swedish carrier ABA, though it wasn’t implemented. In the
meantime, the Ethiopian government was conducting parallel negotiations with the American
government, which led to the signing of an agreement between the two sides for the creation of
an Ethiopian carrier.
Prompted by the American Legation, the US Civil Aviation had on June 12, 1945, drawn
up a plan for an Ethiopian domestic air service, highlighting the political and economic benefits
the country will gain from it. A meeting between members of the Ethiopian Delegation to the
United Nations and the Board Chairman of Transcontinental and Western Airlines (TWA),
Brigadier General T.B. Wilson, was also arranged by the US State Department. Wilson expressed
TWA’s readiness to help Ethiopia start its own airline if it could secure the necessary capital.

The following day, a letter of intent documenting the agreement of both parties to the
arrangement was signed; and a final agreement was inked on September 8, 1945, providing for
the creation of a commercial airline to be known as Ethiopian Air Lines (EAL).

Ethiopian Airlines is the national airline of Ethiopia with its main hub at Bole International
Airport. During the past seventy plus years, the airline has become one of the continent’s
leading carrier, unrivalled in Africa for efficiency and operational success, turning profits for

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almost all the years of its existence. Ethiopian has business units like Ethiopian aviation
academy, Ethiopian maintenance, repair & overhaul, catering, Cargo & logistic services etc.

Ethiopian commands the lion’s share of the Pan-African passenger and cargo network operating
the youngest and most modern fleet to more than 95 international destinations across five
continents. Ethiopian fleet includes ultra-modern and environmentally friendly aircraft such as
Airbus A350, Boeing 787, Boeing 777-300ER, Boeing 777-200LR, Boeing 777-200 Freighter,
Bombardier Q-400 double cabin with an average fleet age of five years. In fact, Ethiopian is the
first airline in Africa to own and operate these aircraft.

Ethiopian is currently implementing a 15-year strategic plan called Vision 2025 that will
see it become the leading aviation group in Africa with seven business centers: Ethiopian
Domestic and Regional Airline; Ethiopian International Passenger Airline; Ethiopian Cargo;
Ethiopian MRO; Ethiopian Aviation Academy; Ethiopian In-flight Catering Services; and Ethiopian
Ground Service. Ethiopian is a multi-award winning airline registering an average growth of 25%
in the past seven years.

1.1.2. Vision

 To become the most competitive and leading aviation group in Africa by providing
safe, market driven and customer focused passenger and cargo transport, aviation
training, flight catering, MRO and ground services by 2025.
 Ethiopian Aviation Academy will be the most competitive and leading aviation
training center in Africa by 2025.
1.1.3. Mission
 To become the leading Aviation group in Africa by providing safe and reliable
passenger and cargo air transport, Aviation Training, Flight Catering, MRO and
Ground Services whose quality and price “value proposition” is always better than its
competitors,
 To ensure being an airline of choice to its customers, employer of choice to its
employees and an investment of choice to its Owner,

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 To contribute positively to socio economic development of Ethiopia in particular and

the countries to which it operates in general by undertaking its corporate social
responsibilities and providing vital global air connectivity.
1.1.4. values and principles of Ethiopian Airlines
 As an airline, safety is our first priority,
 Ethiopian is a high performance and learning organization with continuous
improvements, innovation and knowledge-sharing. We accept change for the growth
opportunity it brings and always seek for and apply the best ideas regardless of their
source,
 We recognize and reward employees for their performance and demonstrate
integrity, respect to others, candor and team work, 
 Act in an open fashion and be result-oriented, creative and innovative,
 Adopt Zero tolerance to indifference, inefficiency and bureaucracy,
 Encourage 360° free flow and sharing of information,
 Treat our customers the same way we would like to be treated and always look for
ways to make it easier for customers to do business with us,
 We are an equal opportunity employer
1.1.5. Strategic Objectives
Based on the Vision 2025 the following are the strategic objectives set for Ethiopian Cargo for
an eventual transformation to a full-fledged profit center.
 Annual freight revenue of 2 billion USD
 Annual total tonnage of 820,000.
 Serving 37 International Freight Destinations.
 Earning annual profit of US$ 200 million.
 Operating 18 Jet Aircrafts.
 Leader in Africa in Quality Cargo Services.
 Fully implement IATA e-freight by 2019 as per revised IATA deadline.
1.1.6. Products and Services of Ethiopian Airlines

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Ethiopian airline provides the following main domestic and international aviation services.

1. Ethiopian Domestic and Regional Airline

2. Ethiopian International Passenger and Cargo Airline
3. Ethiopian Aviation Academy
4. Ethiopian MRO
CHAPTER: TWO
2.1. THE INTERNSHIP EXPERIENCE
2.1.1. General objectives
The internship program has the below objectives:
 To become familiar with the structure of the organization or organizational goal and
objectives, departmental responsibilities and function, project management
procedures, technology assessments and engineering decision making procedures, and
employee performance evaluation and motivation.
 To be able to see how the catering facility cold rooms is designed and review if there
are improvements we can suggest.
2.1.2. Beginning of the internship
The internship program began after being assigned to the specific department by the company
human resource office. The office assigned us based on our department preference and the
departments’ relevance for the intended program.

2.1.3. Trainings
The internship program began by introduction with department staffs and supervisor. Then
briefings and coaching were followed. We have reviewed the organizational structure, rules,
regulations and procedures. We were assigned at Inflight catering facility maintenance and QMS
& EMS.

2.2. Overview of Inflight catering

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The catering unit is built in 1968 on a 3260 square meters of land and expanded in 1986 to
accommodate the growing operational needs of Ethiopian Airlines. Currently we are renovating
the previous building to work in conjunction with the newly inaugurated ultramodern catering
facility built in 2016 on 11,500 square meters.

Fig 2:1. Ethiopian Inflight catering facility

Ethiopian in-flight catering is one of the seven strategic business units (SBU) under Ethiopian
Aviation Group. In total it has more than 650 employees who produce 100,000 meals per day for
passengers travelling on average more than 120 flights. VIP and Charter flights which often
shuttle to and from the Addis Ababa Hub are prominent customers of the catering unit. The
Catering unit is strictly guided by HACCP policies and procedures which promote a high level of
quality management for the safe production and handling process of all catering services.

In line with the ETHIOPIAN’s vision, the catering unit is newly structured and organized as a
strategic business unit (SBU) consisting of seven sections including the department of In-flight

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Catering Quality Management System & Safety Management System, Food production,
Operations, Procurement and supply chain, HR development & Finance- Catering, Route catering
and Catering facility maintenance. 

Among other things, the existing catering unit is equipped with:

 High-tech cooking and bakery equipment

 Large capacity dish, glass and pot washing machines
 Flow wrapping machines
 Heavy duty ice cube machines and dry ice supply
 Fifteen high lift trucks and four vans
 Cold rooms, freezers and chillers
 Perishable and dry food items store
 Laundry and dry cleaning service
 Large bonded stores area

Ethiopian in-flight catering services provide the following services:

 Food & beverage to VVIP, commercial flights, charter flights and private jets
 Business Class Lounge
 Supply of in-flight catering service items
 Belly-galley service
 Halal kitchen service

All the above details show how major Inflight Catering operations is to Ethiopian airlines
operation in general. Every flight whether its domestic or international flight, different meals,
snacks drinks etc. will be loaded by the Inflight catering. Therefore, in order for a flight to depart
on its scheduled time, on time performance by various sections including Inflight catering is
mandatory. Accordingly, one dedicated department was established to smoothen Inflight
catering has vast number of facility and equipment for its operation. Hence it needs

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maintenance section accordingly. The inflight catering facility maintenance section has the
below structure

2.2.1. Organizational structure

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Organization Structure of Equipment & Facility Maintenance Departement

Chief Executive Officer (CEO)

Chief Operating Officer (COO)

Director Equipment and Faility

Maintenance

Administrative
Assistant

Team Leader
Team Leader
Planning and Manager GSE/GTV Manager Facilities
Maintenance
Engineering Maintenance Maintenance
Inspection
Support - EFM
Team Leader MRO
Team Leader GSE
Facilities &
Mechanical
Laundry
Maintenance (2)
Maintenance
Team Leader
Team Leader GTV
Airport, Domestic
Mechanical
&HO Facilities
Maintenance (2)
Maintenance
Team Leader GSE Team Leader
Electrical Building and
Maintenance Carpentry Works

Team Leader GTV Team Leader

Electrical Laundry services
Maintenance

Team Leader Team leader EAA

Engine O'Haul & Facilities Mgr. Academy
Services
Tire Repair Maintenance
Team Leader Team Leader ET
GSE/GTV Paint, Inflight Catering Dir. ET Inflight
MD.Ground service
Body & Interior Facilities Catering
Maintenance Maintenace
Team Leader Mgr. Cargo
Cargo Facilities Infrastructure Dev't
Maintenance & Mgt.

Fig 2:2 organizational structure

2.2.2. Basic function of inflight catering facility maintenance
The unit performs Electrical and Mechanical works at inflight catering based on
 Repair and maintenance work of
 Routine maintenance for all machineries and equipment
 preventive maintenance for all machineries and equipment
 brake down maintenance for all machineries and equipment

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 Installation work for;

 Water line
 High pressure Gas line
 Electric line
 Fuel line
 Drainage line
 cold rooms, refrigeration and air conditioners
 industrial Machineries
 Water & chemical pumps
 Machine Erection
 Manufacturing and construction
 All metal works
 Office partition
 office furniture
 kitchen tables
 Carts and trollies
 Cargo X-ray Machine
 Kitchen Equipment

 Provides electrical power, AC and DC voltages to the standards.

 Commissioning
 Machineries
 Power system
 Cold rooms and air conditioners
 In building facilities

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CHAPTER: THREE
3.1. PROJECT: Catering Cold Rooms Failure Maintenance.
3.1.1. Introduction
This report presents a brief description of the current Ethiopian in-flight catering cold rooms
system. Its maintenance procedure some major problem and investigating the cause of failure to
solve it.

3.1.2. Statement of the problem

Ethiopian Inflight catering has vast number of cold rooms that are installed by different
companies. This machinery’s due to service time and mostly the problem of installation failure.

3.1.3. Scope of the work

The project focuses working principle of cold rooms and investigate emergency failure to give a
proper maintenance.

3.1.4. Objectives
3.1.4.1. General objective
 To gain experience in the non-academic, technical and business activities of the
company
 To be aware of the industry standards, ethical practice, policy, procedure,
service and the interaction between the company and the industrial
environment.
 To understand the sustainable cold rooms working system at the catering
facility
3.1.4.2. Specific objective
 To be familiarized with actual equipment at the catering facility
 To solve the emergency failure of cold rooms.
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3.1.5. Methodology
The following steps were followed to get access.
1. Company manual
2. Company facility engineering department
3. MISA& Celtic companies Technical Team
3.1.6. Materials and Tools Used
1. Company portal page
2. Shop common tools and individual tools
3. Company PC

Some of the major machineries and equipment are discussed in detail below;

1- Dish washing machine

Ethiopian catering has four dish washing machine that’s use to clean and reuse plate, cups, bolls
and so on food handling equipment. This machine has three main sections.
1. Washing section
2. Raines section
3. Drier section
During ON the machine first it’s fill the water at washing tanker, rains tanker and booster tanker
through water solenoid valve. When the tanker fully filled by water the water level sensor cut off
water solenoid signal and on heating cycle. Then the washing temperature reached after some
minute depending heaters KW efficiency. Finally, automatically the machine display machine
ready for operation text then the operator operates the machine and do their work.

2- Rational oven machine

The machine installed at hot kitchen area. It’s self-cooking and modern as 5 sense machine. Its
cook likes chicken, fish, meat and so on food types by using steam, dray heat and steam with
dray heat cooking program. The main section of this machine is:

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1. Dryer heater section

2. Steam section
3. Processor card and control card
4. Blower fan motor and SSR
This machine has Owen self-test function access on the controller software. All machine
components were under this software controlled. If its machine has alarm or disaffection, we
can know simply which component are failed by using this self-test function button.

3- Ice maker machine

Ice maker machine is one of catering heavy duty machine. Its produce solid ice for each flight.
The working principle is almost the same with cold room. It uses condenser unit, evaporator unit
and compressor. This machine has separate water line system. The gas line cooled the water
molded plate by direct conduction heat transfer system and the water gradually create solid ice
mold by driven with water line by force of pump motor. Finally, while the system finish freezing
cycle it realizes hot gas for ditched solid ice from the plate and collect ice at down bin.

4- Astrophysics X – ray machine

As Known aviation industry needs special security department. So Ethiopian in-flight catering
also uses three cargo type Astrophysics X – ray machine for perishable food items, for water and
duty free packed goods. This machine has the below main parts.
1. X – ray generator
2. Conveyer section
3. LXDA section
4. PLC section
5. DCI section
6. Screen section
7. Switch, sensor section and software application.

During ON the key on the key board the system was initialize overall system and ready for
operation if there is no alarm on the system, then we can scan the picture from two side from
top and side view. When unwanted material putted inside the packing the X – ray detect by
color and give message with alarm.

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3.2 Project work on Cold room machinery

Food needs special treatment and preserving otherwise simply its developing bacteria. For
protect food poisoning inflight catering have above 20 cold rooms and 6 Freezers. All cold rooms
are commercial type so they have indoor and outdoor units. There are two brand types which is
MISA Italian and CELTIC Netherland Machineries. The technical application on the units have
different. This Two brands installed by out of the company technical team.
3.2.1 Each type’s product specification
In the world cold room technologically have common principles of product specification this
common unit are
1. Evaporator unit
2. Condenser unit
3. Compressor.
4. Expansion valve

But manufacturers have there are unique product specification for customer need
 MISA product design

Fig. 3:1 MISA cold room outdoor unit

There are above 20 cold rooms and two freezers in this brand installed in Ethiopian catering.
Most of its unit similar model. Its plant was designed and built for installation cold room to be

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used commercial purpose. It basically consists of a condensing unit, suitable for installation
outdoor unit which is closed by non-toxic plastic coated sheet metal, the controlling unit and
indoor unit. The controlling mechanism was more electronics which is PLC. The outdoor unit
consists of motor composer which is semi-hermetic piston type, condenser and controlling PLC
unit. Most commercial types have liquid receiver and oil separators included but those
machineries do not have it, instead of that there are different types of solenoid valves inserted.
The indoor units consist of Evaporator and expansion valve working gas 404A.

 CELTIC product Design

Fig.3:2 CELTIC cold room condenser unit

This cold room machinery in Ethiopian catering installed before new catering build so they are
old also they are re installed after completion of new building, there are 3 freezers by this type.
All are electro mechanical devises and the outdoor unit include condenser, semi-hermetic piston
type compressors, oil separators, liquid reservoir, electrical and mechanical controllers. Indoor
unit is similar which have evaporator and expansion valve working gas 404A.

3.2.2 Advantage and disadvantage of each Products

MISA CELTIC
 Easily diagnosis - complicated to diagnosis
 Integrated in one unit - separated each component
 Space utilized - space consume when installed
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 Skilled person for maintenance - easy to maintain

 High cost for maintenance - low cost for maintenance
3.2.3 Tools for maintenance of Cold rooms
 Pressure gage
 Vacuum pump
 Recovery pump
 Wrench’s
 Oxy-acetylene
 Filer rood
 Fleering tools
3.3 Emergency failures and troubleshooting

3.3.1 Dispatch holding room motor failure

Dispatch holding room is the final prepared foods for loading in flight holding for specific time so
this prepared food to be cold until it loaded flight to prevent atmospheric temperature. On
dispatch holding there are two unite installed. They work with same period b/c they have
common room sensor. When walk around controlling one of its unit with a time interval it shut
off the unit.

Trace the problem

When trace the problem the starting and working current of motor are the same so we decide to
replace new one.

Procedure to replace new motor

 Switch off main power breaker
 Suction line valve closed
 Discharge line closed
 Recover gas from fail motor
 Disconnect all sensor from failed motor
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 Dismantle suction & discharge line

 Replace new motor
 Connect all dismantled parts
 Open the line
 Charge the same amount of gas which is recover
 Start Up the unite

Investigating the root case

When we investigate the problem we have gate high temperature over the outdoor unit it
comes from manifold of main generator when power interrupted stand by generator runs until
the main power comes, so the manifold located on the tops of the unit.

Final Correction action

The team decided to the top of the cold room unit by heat resistance sheet laminated bonded
foam.

Fig. 3:3 before and after maintenance of dispatch holding

3.3.2 Store freezer oil separator failures

The unit is CELTIC freezer. The problem occurs during shipping motor unit when installed. First
we try to solve the problem by arc welding b/c we don’t have the part on hand. It works for a
few time but the line is discharge so in some extent leaks gas and liquid.

Final action taken

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We order the part urgently when the part came to our hand announce to the user department
to reduce stoke on the unit b/c there is another unit doesn’t take the load.

The gas totally recovers in tanks. Then replaced new part by oxy-acetylene welding. After
welding vacuum, the line then top-up the oil by checking on site glass and gas recharged to the
system which is recovered.

Fig. 3.4 before and after maintenance of oil separator

3.3.3 Store freezer suction line to control vale joint leakage

There are two perishable food item store freezers located in ground flower which is installed by
CELTIC. Each store freezers have tow unite on the room.one of unit indicated shortage of gas.
Shortage of gas determined by accumulation of ice on evaporator unit and also intermittent
motor operation and by reduce gas pressure in gage. When we observe this indication we trace
the place of leakage by leak detector finally we get the place the problem comes due to un
proper covering of insulation.

Correction action

After gating the place, the gas pump down to liquid tanker then dismantle suction valve and cut
copper line from the valve then braze by oxy-acetylene. After finish brazing the valve connected
to the motor then vacuum the line then released the gas by opening the tank valve a little
amount of new gas charged until the gage set pressure.

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Fig.3:5 before and after maintenance of joint leakage.

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CHAPTER: FOUR
4.1. Benefits Gained from internship
The industry internship program has helped us in various aspects described in detail below.
We have general understanding of how different machine like dish washing machine, rational
oven machine, ice maker machine and X – ray machine works. We are familiarized with cold
room system to the whole catering facility. This internship program allowed us to work and
understand different electrical equipment. Accordingly, we learned practical concepts that we
did not adequately discussed in classroom. To mention a few,
1. General familiarization of the facility maintenance works.
2. Familiarization of cold room system.
3. Familiarization of equipment like dish washing machine, rotational oven machine,
ice maker machine and the nature of load of this equipment.
4. Team work and work ethics.

CHAPTER: FIVE
5.1. Conclusion and Recommendations
5.1.1. Conclusion
In conclusion, we are satisfied with the whole internship program. The cold room system of the
facility and the working principle of various machines are related to academically learnt
knowledge at university. We have learned many new technical subjects, acquired a number of
new technical skills and improved team work skill.
We can confidently say that this internship has had significant impact on our technical and soft
skills. We have achieved the purpose this internship is intended for.
1. Recognizing new equipment’s and learning about them.
2. Large improvement on our understanding on practical maintenance of cold room
equipment’s.
3. Gained the ability to execute tasks given by supervisors.
4. Gained practical knowledge to Kitchen equipment’s.

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5.1.2. Recommendation
During our internship program we have been familiarizing with cold rooms to catering facility.
Accordingly, we have some recommendations stated as below;
The cold room installation of the inflight catering facility is poor and could significantly affect the
whole inflight catering operation. Which directly related with high customer inconvenience and
very high cost. Therefore; we recommend Inflight catering to investigate all cold room
installation and improve with standard installation system to protect frequent maintenance
problem.
Another recommendation we have is that the work environment is very demanding and most of
the senior staffs are too busy to assist and brief us until they get relatively free time. Therefore,
we suggest that the company assign dedicated staff who will engage interns to practical works.
As internship program is should mostly practical, the time spent to read various manuals and
other references was relatively more. Therefore, this way of attending interns should be
changed.
In conclusion, we believe we had good internship period and we have achieved the intended
purpose satisfactorily. However, a general recommendation to the company is to find ways to
use interns as one resource and make good benefit of them rather than considering them as
client or customer.

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5.1.3. Reference
1. Ethiopian Airlines Web site
https://www.ethiopianairlines.com/AA/EN
2. Ethiopian Airlines portal page:
http://portal.ethiopianairlines.com/Lists/Ethiopian%20Group/Tiles.aspx
3. Facility maintenance equipment manual
4. Other company documents

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