This can be used as a sample for student studying fifth semester electrical for case study of instrumentation subject. Hope you guys enjoy it and remember my name Diwakar Karn😇

1. A REPORT ON
INSTRUMENTATION-II CASE STUDY
Submitted By:
Diwakar Karn (076BEL-016)
Madan Bohara (076BEL-022)
Ramansu Kumar Jha (076BEL-034)
Submitted To:
Department of Electronics
and Computer Engineering
IOE Pulchowk Campus
Lalitpur, Nepal
Visit Undertaken At
Aqua World Pvt. Ltd
Gokarneshwor-8, Kathmandu

2. ABSTRACT
Learning is a continuous process that happens throughout our whole life. It is what continues
to encourage people to acquire knowledge and develop new skills. The concept of education
and learning is not only confined to classrooms and pre-defined place in this modern
technological society but also has expanded to various arenas where growing every day and
improving ones skill matters the most. To aid a practical experience to our academic career,
we were assigned to conduct field visit where we could link the pre-existing system with the
instrumentation based design to make it more robust and provide a better alternative to it. The
main motto of this field visit was to relate the things taught in the classroom and labs with the
real world.
We visited Aqua World Pvt. Ltd. located in Gokarneshwor, Kathmandu. This company
provides good quality of water packed in 20 litres of plastic jar. It processes water obtained
from Underground and Spring Water and purifies it at different levels and remove all the
unwanted materials from it and making it safe for drinking purpose. All the treatments are
done inside the factory itself and that’s why we chose this as our visit site. It met all the
criteria which we wanted to relate with our current syllabus.
Keywords: Treatment, Processing, Filtration, Purification, Ozonolyis, System,
Automation
 Diwakar Karn
 Madan Bohara
 Ramansu Kumar Jha

3. ACKNOWLEDGMENT
We would like to express our special thanks of gratitude to our teacher, Sanjivan Saytal as
well as all the lecturers and professors of Electrical Engineering Department, Electronics and
Computer Engineering Department of IOE Pulchowk Campus for giving us the golden
opportunity to do this wonderful project of field visit and relate the pre-existing system with
the technology and knowledge we have learnt in our lab and classroom. This helped us
greatly in doing a lot of research and we came to know about so many new things and we are
really thankful to them.
Secondly we would also like to thank to the team of Aqua World Pvt. Ltd. especially Mr. Shri
Shrestha Sir for letting us to visit his factory and Mrs. Bibita Joshi for guiding us with the
working principle and machines associated with the water treatment and purification. Without
them, this project would just have been confined to paper.
Last but not least, we’d like to express our warmest thanks to our team members for their
work division and interaction with the concerned person in field.
THANK YOU!!!

4. CERTIFICATE OF APPRECIATION

5. TABLE OF CONTENT
 Abstract……………………………………………………………………….
 Acknowledgement………………………………………..…………………..
 Certificate of Appreciation………………………………………..………….
 Introduction to Water Purification……………………………………………
 History and Service Provided by the Company………………………………
 Methodology……………………………..…………………………………...
 Processing System
 Existing System of water processing and treatment
 Illustrative representation of the existing model
 Dispatch and delivery of water jars
 Illustration showing receiving and dispatch of water jars
 Recommendation of the system………………………………………………
 Jar Washing
 Water filling
 Description of Proposed System
o Algorithm and Code
o Circuit diagram
o Component description
o Cost for installation
o Automation in Water level System
 Advantage of Installation of Proposed System……………………………….
 Discussion and Conclusion……………………………..…………………….

6.  Introduction to Water Purification
Water purification is the process of removing undesirable chemicals, biological contaminants,
suspended solids and gases from contaminated water. The goal is to produce water fit for a
specific purpose. Most water is purified for human consumption (drinking water), but water
purification may also be designed for a variety of other purposes, including meeting the
requirements of medical, pharmacological, chemical and industrial applications. In general
the methods used include physical processes such as filtration, sedimentation, and distillation,
biological processes such as slow sand filters or biologically active carbon, chemical
processes such as flocculation and chlorination and the use of electromagnetic radiation such
as ultraviolet light.
Lack of clean drinking water leads to dehydration of the body and other health complications.
For this reason, governments and water supplying companies ensure that people have access
to clean and safe water for domestic use. Clean water is essential in ensuring that no
pathogens or impurities are ingested by people, either through direct drinking or through
food. To attain these standards of water, purification is important. Water purification involves
physical and chemical processes, which are carried out stepwise to ensure the water is safe
and free from any harm. This directional process essay synthesizes the steps, which have to
be followed to achieve this task.
In essence, water purification denotes the process used to free water from impurities
likebacteria and contaminants. Since the process is aimed at eliminating all the impurities
present in the water, it is necessary to apply chemical and physical methods of separation in
an orderly manner. Nevertheless, the steps involved depend on the nature of impurities
present. An important fact is that the water, which people consider to be pure, could be highly
toxic, including rain water, which has a host of dissolved chemicals and dust. On the other
hand, water from rivers is considered to be more contaminated than that from wells. As a
result, the former requires more purification steps. So, purification of water has been a major
concern in these days especially in Kathmandu Valley where the sources of water are
polluted in extreme level.
 History and Service Provided by the Company
Aqua World is jar water processing company continuing its service over a decade. It provides
jar water with free delivery in Kathmandu valley. One can order online from the website and
from their mobile apps by a simple login. They aim to provide best and pure jar water door to
door in Kathmandu valley with a motto of “Make sure, Drink Pure” Aqua world is Nepalese
Company registered under the company act of Nepal government. Department of Food
Technology and Quality Control and Department of Cottage Industries regulate them.

7.  METHODOLOGY
 Processing System
Water is obtained as spring water or from groundwater. The water is then collected in a
sedimentation tank. The simple process of sedimentation allows heavy particles to settle down.
After this following are the steps to be followed in water processing system:
1. Chlorination
2. Sand Filtration
3. Carbon Filtration
4. Candle Filtration
5. Micron cartridge Filtration
6. Reverse Osmosis RO
7. Ozonation
8. UV Water Purifier and Polishing Filter
a. Chlorination
Groundwater is stored in the tank with the help of a pump and chlorination is done with 2-3 ppm.
Chlorination is the process of adding chlorine or chlorine compounds such as sodium
hypochlorite to water. It is done to kill viruses, bacteria, and other microbes present in water. It
prevents the spread of waterborne diseases such as cholera, dysentery, and typhoid.
b. Sand Filtration
In this process the filtration of water is realised by the ‘porous’ nature of a sand layer which traps
particles present in the water. Sand filtration is used in treatment of groundwater to remove
dissolved iron. Iron and manganese in the flocs formed are trapped in the sand filter. Sand filters
are cleaned by backwashing with air and/ or water. The medium of the filter is sand of varying
grade. As water passes through the sand, impurities such as solids, precipitates, turbidity, and in
some cases even bacterial particles are filtered out,
c. Carbon Filtration
Carbon filters are most effective at removing chlorine and volatile organic compounds from
water. Water is treated by carbon filters using a process called adsorption. When water is passed
through the activated carbon, the carbon acts like a sponge with a large surface area and absorbs
the contaminants in the water.
Carbon filters are produced by grinding up a carbon source. Mostly coconut shells. To create the
filter, material is heated in the absence of oxygen to 2000 degrees to bake off impurities. Then it
is subjected to 1600 degree steam to activate the carbon. The steam leaves carbon granules filled
with cracks and pores enabling them to store large amounts of chemicals and contaminants.

8. d. Candle Filtration
With the help of a pump, water is passed through a tube-like structure on the inner part of the
pressure vessel. As the water flows, the filter candle holds contaminants thereby filtering water.
Candle filters consist of tiny versatile pore structures which are responsible for the efficient
filtration of pathogens present in the water.
e. Micron Cartridge Filtration
Micron filtration is done to filter water in micron rating. A pump passes the water at high
pressure through 0.0001 micron pore-size cartridges to separate suspended particles from
processed water.
Before the further treatment of water, a micron lab test is done.
f. Reverse Osmosis RO
After the compilation of primary purification reverse osmosis is performed. The term reverse
osmosis comes from the process of osmosis, the natural movement of solvent from an area of
low solute concentration, through a membrane to an area of high solute concentration if no
external pressure is applied. It is a system which separates the pure water from contaminated
water. Water is forced at high pressure through a semipermeable membrane. A semipermeable
membrane has small pores that block contaminants like fluoride, chlorine, and other harmful
dissolved chemicals but allow water molecules to flow through. Water flows from the more
concentrated side of the RO membrane to the less concentrated side to provide clean drinking
water.
g. Ozonation
Water is stored into large tanks and ozone is passed through it with the help of ozonator.
Ozonation is done to remove the microorganisms from the water. Ozone is efficient for
disinfection as well as for the degradation of organic and inorganic pollutants. Ozone is an
excellent sterilising agent without any effects. As ozone is unstable it breaks down into oxygen
molecules after some time. Ozone is produced with the use of energy by subjecting oxygen to
high electric voltage or to UV radiation.
h. UV Water Purifier and Polishing Filter
This is the last step before transferring water to the product water tank. A UV water purifier
exposes remaining microorganisms to a germicidal ultraviolet wavelength of high energy, which
disrupts the DNA in pathogenic microorganisms so they cannot reproduce.
Polishing is the post filtration process. This causes the microorganisms to attach to the filter and
make water smoother.

9.  Existing System of water processing and treatment
Fig: Existing System of Water Processing and Treatment
 Illustrative representation of the existing model
Groundwater /
Spring Water
Sedimentation
Chlorination
Sand
Filtration
Carbon
Filtration
Candle
Filtration
Micron
Cartridge
Filtration
Reverse
Osmosis
Ozonation Polishing
Filter
UV Water
Purifier
Product
Water
Tank
Ground Water
Sedimentation
Chlorination
Sand filtration
Control Panel
Carbon,
candle and
micron cartage
filtration
UV Water
Purifier
Reverse
Osmosis
Ozoniser
Final Water
dipatch
High Pressure
pump
Jar cleaning section
3D MODEL OF WATER PROCESSING & TREATEMENT AT AQUA WORLD LTD.

10.  Dispatch and delivery of water jars
After the successful completion of phase-I regarding the treatment of water for purification, the
jars are ready to refill with pure drinking water. This phase is concerned more with the
commercial aspect which involves direct involvement of manpower more than the use of
machines but even this phase needs automation and interaction with the concept of micro-
controller so that work can be done more effectively with the help of the developed embedded
system. Each of the sub-process in second phase is described below:
a. Receiving of Jar: Jars from various part of Kathmandu are received via jeeps and
other vehicles. The unloading is done manually which may involve the
deterioration of the plastic jar base over a period of time. So, we have noticed the
base of jar being rough, weakened and some may even have holes and leakage
section. This can be avoided by introducing the section and compartment so that
unloading can be done with large volume at a time.
b. Rinsing of Jar: A machine is used for rinsing jar inside portion by raw water.
The empty jar is placed in invert position on the rinsing jacket manually and push
button is switched on which is provided in control panel. Rinsing takes place in
three different sections. The procedure is done with the normal water from the
nearby water source with little treatment. This machine is very compact &
economical machine. It is easy to operate and maintenance free machine.
c. Bottling and labelling: After proper washing of the jar, the water is filled
manually by the human taking hygiene in utmost care. Six different outlets are
operated at one time and around 3000 of jars are refilled on the daily basis in
current time. However the bottles and caps are imported from the external plastic
factory with the contract. In addition to it, the name and logo of the company
plastic attached over the jar are also dealt with the same plastic company. Since
this process is linked with external factors, so we don’t think for any sort of
improvement and modification in the phase.
d. Storage of jars: The process of refilling and delivery are completely sequential in
nature that the storage doesn’t take larger area and duration. However, under
some circumstances like curfew days when jar delivery is completely restricted
via vehicles, the storage of jar is taken into the matter of consideration. It is
prescribed to have stored in cool temperature and direct sunlight is avoided. The
jars should be stacked horizontally on ground without making piles.

11. e. Dispatch: After arrival of the vehicles, they are taken to the respective retailers.
This process is again done manually which takes considerable time in loading of
jars in the vehicles. So, the concept of automation can be implied here which
might take greater initial cost and may not seem worth for saving that time.
However this process can be beneficial not in only saving the time but also the
labour cost.
In every process, the quality of the work is checked and a skilled manpower is employed to do
so. The water sample is checked once in a week in the production house itself which involves
physical test like colour, turbidity, odour and taste, chemical test like pH and BOD. High B.O.D.
means that there is less of oxygen to support life and indicates organic pollution. For
bacteriological test, the water sample is sent to Kathmandu Upatyaka Khanepani Limited (KUKL).
For technical and economic reasons, analytical procedures for the detection of harmful
organisms are impractical for routine water quality surveillance. It must be appreciated that all
that bacteriological analysis can prove is that, at the time of examination, contamination or
bacteria indicative of faecal pollution, could or could not be demonstrated in a given sample of
water using specified culture methods. In addition, the results of routine bacteriological
examination must always be interpreted at KUKL. The water sample is sent once in a month at
KUKL. This entire phenomenon is called QC Inspection and done by Production and Quality
Manager.
The sequential diagram of this phase can be shown as:
Fig; Illustration showing receiving and dispatch of water jars
Recieving
of Jar
Rinsing Bottling Labeling Storage Dispatch

12.  Recommendation of the system:
In the above manufacturing process jar washing and filling should be done by using some
automatic system. As a recommendation we propose a conveyer belt system driven by DC motor
and controlled by microcontroller.
JAR WASHING:
In this section a rotating brush can be fitted for each jar followed by external wash with the help
of fixed brush, this time jar is rotated.
Frame fitted with brush
Rotating brush for inner wash Outer wash Rotating jar
WATER FILLING:
After filling the jar is passed to the filler with conveyer belt and filled accordingly. This system
is designed for six jars as there are only six tap in plant.
1 • Manual fitting of each slot
2 • Inner wash
3 • Outer Wash
4 • Filling of jar

13.  DISCREPTION OF PROPOSED SYSTEM:
Firstly, each jar is placed on dedicated slots fitted with rotating brush. Slots provide water and
wash the inner portion of jar. This process is followed by outer wash for each jar outer wash is
performed for 0.5 minutes. This is done by programming microcontroller such that it off the
relay for 0.5 minutes so conveyer belt stops. After outer wash jars are moved to the filling
section. In this section six jars are fitted with six fillers and jars are moved with filler in forward
direction. Microcontroller is programmed such that time require to travel horizontal distance is
exactly equal to filling time.
 ALGORITHM:
1. Start
2. Fit the jar in dedicated slot
3. Rotate inner brush for 0.5 minutes
4. Rotate jar for 0.5 minutes for outer wash
5. Fit filler to jar
6. Move both jar and filler at same speed
7. Repeat from 1 until production is done
8. Stop
Here, in this case arduino is used. Simple code for digital write is written below for switching
purpose of relay:
Int signal=12;
Void setup ()
{
pinMode(signal,OUTPUT);
}
Void loop ()
{
digitalWrite(signal,low)
delay(15000)
digitalWrite(signal,high)
delay(9000) //it takes 0.3 sec for bottle to arrive at outer wash frame
}

14.  CIRCUIT DIAGRAM:
Fig: Circuit for controlling motor by arduino with relay
Component description:
Diode: It is 10A04 silicon diode. Ratings are :400V,10.0A
Capacitor: 200v, 820pf
Relay: 5v coil.
Microcontroller: Arduino R3
DC motor: 220v, 1.5 HP
Cost for installation:
Material Cost
Conveyer belt 2m Rs.38400
DC motor Rs.9750
Microcontroller Rs.1300
Others Rs.5000
Total: Rs.54450
RL1
G5C-1-DC5
DIGITAL (~PWM)
ANALOG IN
ATMEGA328P-PU
1121
~
~
~
~
~
~
microcontrolandos.blogspot.com
TX
RX
PD0/RXD
0
PD1/TXD
1
PD2/INT0
2
PD3/INT1
3
PD4/T0/XCK
4
PD5/T1
5
PD6/AIN0
6
PD7/AIN1
7
PB0/ICP1/CLKO
8
PB1/OC1A
9
PB2/SS/OC1B
10
PB3/MOSI/OC2A
11
PB4/MISO
12
PB5/SCK
13
AREF
PC5/ADC5/SCL
A5
PC4/ADC4/SDA
A4
PC3/ADC3
A3
PC2/ADC2
A2
PC1/ADC1
A1
PC0/ADC0
A0
RESET
DUINO1
ARDUINO UNO R3
+88.8
D1
10A04
D2
10A04
D3
10A04
D4
10A04
C1
820pF
D2(K)
DC MOTOR
RELAY
RECTIFIER USING HIGH VOLTAGE DIODE
AC SUPPLY

15.  Automation in water level sensor of storage tank
While discussing about the working methodology, we also came to know about the fact that one
person is employed specifically to check the level of water time and again to deal with the
switching of motor. However this can be minimized to automation by the use of automatic water
sensor which would mark the level and the synchronous speed of motor can be operated on the
required basis. When water flows through the valve it rotates the rotor. By this, the change can
be observed in the speed of the motor. This change is calculated as output as a pulse signal by the
hall effect sensor. Thus, the rate of flow of water can be measured.
The main working principle behind the working of this sensor is the Hall effect. According to
this principle, in this sensor, a voltage difference is induced in the conductor due to the rotation
of the rotor. This induced voltage difference is transverse to the electric current. When the
moving fan is rotated due to the flow of water, it rotates the rotor which induces the voltage. This
induced voltage is measured by the Hall Effect sensor and displayed on the LCD display. We
achieve this by use of 8086 microprocessor where the LED and motor is synchronized with the
system.
The water level will show indication mark and will be categorized into eight different levels as
shown in LED display and will work with the motor in the similar manner and if it reaches at the
eight positions it will be designed in such a way that it will automatically off the switch without
any manual switching system. This method employed is quite effective and accurate for the
measurement of the water level.

16.  The code written in 8086 assembly language is mentioned below:
DATA SEGMENT
msg1 db 10,13,"The water level is: $"
msg2 db 10,13,"Switch ON motor. $"
msg3 db 10,13,"Switch OFF motor. $"
msg4 db 10,13,"Water overflow! $"
DATA ENDS
CODE SEGMENT
ASSUME DS:DATA,CS:CODE
START: mov AX,@data ;intialize data segment
mov DS,AX
mov CL,1H
L1: lea DX,msg1 ;displaying water level message
mov AH,9H
int 21H
add CL,30H ;ASCII adjust before displaying
mov DL,CL
mov AH,2H ;display
int 21H
sub CL,30H ;ASCII adjust after displaying
cmp CL,8H ;switch off motor
je off ;jump to off if = 8
cmp CL,1H ;switch on motor
je on ;jump to on if = 1
back: inc CL ;increase water level by 1
cmp CL,8H ;check if water level is overflowing
jle l1
jmp exit
on: lea DX,msg2
mov AH,9h
int 21H
jmp back
off: lea DX,msg3
mov AH,9h
int 21H
lea DX,msg4 ;displaying overflow
mov AH,9H
int 21H
jmp back
exit: mov AH,4CH
int 21H
CODE ENDS
END START

17.  ADVANTAGE OF INSTALLATION OF PROPOSED SYSTEM:
1. The production rate will hike to a greater percentage which would yield a better profit
with less manpower.
2. The quality of work will have a progressive change with the installment of the
3. Workers do not have to work in water and chlorine whole day, so a healthy ecosystem
can be experienced.
Remark: The proposed system component rating calculations and system may have to be
modified more or less during implementation.
 DISCUSSION AND CONCLUSION
This field visit of instrumentation case study at Aqua World Pvt. Ltd. was a huge eye opening
experience for us regarding the industrial working methodology. Field trips create opportunities
for students to acquire practical technical skills alongside individual and social experiences. It
gave us a better visualization of how automation and control, power system and human
involvement are synchronized with one another and work together to achieve a desired output.
The site we visited was a water purifying factory which sells jar commercially in the market. It
fulfilled all the standard of water quality tests and procedure of purifying water and making it
safe for drinking purpose. The report discusses about all the process starting from water inlet
from underground to purifying at various level viz. sedimentation, chlorination, and sand
filtration, carbon filtration to Ozonolyis and UV filtration along with the dispatching to the
customer. The process was quite simple and organized with plenty of resources for removing all
the impurities present in the water. However, the entire system still needs some modification in
various aspects including water level sensor, cleansing process of jar, loading and unloading of
jar for its durability and proper cooling system present in the site. In addition to it, there is a
scope of digitalizing control panel so that it can be operated remotely using computers and
microcontrollers making it more robust system. Besides this, at every purification stage, testing
of water sample can be installed and monitored regarding its quality which will make it to sort
out any impurities and restart the process at early stage. However, this will make the system
more complex and may require additional cost which might be expensive for medium
enterprises. So, we have to restrict our report for all categories of concerned factory.
In a nutshell, this field visit gave us a better insight to look into the system and
technology through a new perspective and relating the theoretical knowledge gained in
classroom with the practical experience in modern technological society.

18. PHOTO GALLERY
From left: Chairman-Aqua World, Diwakar Karn, Ramansu Jha, Madan Bohara, Prod. & Quality Manager