DEPARTMENT OF ELECTRICAL AND INFORMATION ENGINEERING

FACULTY OF ENGINEERING

UNIVERSITY OF RUHUNA

INDUSTRIAL TRAINING REPORT SUBMITTED IN PARTIAL FULFILMENT

OF THE DEGREE OF BACHELOR OF SCIENCE IN ENGINEERING

1st June 2015

STATE DEVELOPMENT &

CONSTRUCTION CORPORATION

(From 26th

January 2015 to 24th

April 2015)

MADHURANGA S.H.R (EG/2012/1986)

2 | P a g e

PREFACE

This report was prepared in relation to the Industrial Training Program for

Engineering Undergraduates conducted by University of Ruhuna. The training period

was 12 weeks at State development & Construction Corporation. Normally SD&CC is

doing construction. There are three division included as the construction division,

mechanical division and designs planning & production division. I had my training

related to traffic light system unit (TLS unit) which is the sub division of mechanical

division.

SD & CC do the traffic light projects of International Construction

Consortium (Pvt) Ltd (ICC) and Road Development Authority (RDA). Their traffic

light systems are installed in Matara , Colombo , Kandy , Galle road and etc. All the

projects are consulted by two electrical engineers and one computer programmer. And

also they have trained supervisors , electricians and labours.

In the beginning they used PIC (Peripheral Interface Controller) based traffic

light controller unit which introduced by faculty of engineering, university of

moratuwa. But now they use PLCs(Programmable Logic Controllers) to control the

traffic lights because of the easiness of programming , reprogramming , repairing and

reliability. And also they improved their lighting system and added some extra

facilities. As the examples they change from halogen bulb to LED bulb arrays. And

now they used three colour count-down , two colour pedestrian count-down , two

colour running man or normal man , loop detectors , pedestrian camera & push

button, traffic officer on/off switch or remote controller and fiber optics linking.

According to that I had good experience about traffic light control system

which use in Sri Lanka. As an engineering student I was lucky to have this valuable

and rare chance to have my first industrial training experience at State Development

and Construction Corporation where I was able to gain great work place experience

and technical knowledge.

Madhuranga S.H.R.

EG/2012/1986

Department of Electrical and Information Engineering,

University of Ruhuna.

3 | P a g e

ACKNOWLEDGEMENT

I would like to thank some persons and organizations who really helped me

during the training period. First of all I take this opportunity to express my profound

gratitude and deep regards for Director Dr.J.M.R.S Appuhami who coordinated and

guided us in selecting training places and taking all the arrangements to make it more

successful. And also I express my deep regard for Dr.Keeerthi Gunawickrama, Head

of the Department, Electrical & Information Engineering and all the academic and

none-academic members of my faculty who associated to arrange my industrial

training at State Development and construction corporation.

My sincere gratitude goes to Engineering Education Center of Ruhuna

Engineering Faculty for giving me this opportunity and also to NAITA for granting us

for the training.

I convey my special thanks to Mr. D.M.N. Kanchana, the software developer

& designer at SD & CC who arranged my Training Plane. And also I would like to

thank Chief Electrical Engineer Mr. P.S.R Perera , Electrical Engineer M.A.W.S

Udayarathne , Mechatronic programmer Mr. Dasun and all the TLS Supervisors and

Electrician at State Development & Construction Corporation.

My heartiest gratitude goes to my parents, my brothers and friends who helped

me a lot to make my industrial training a success .The blessing, help and guidance

given by them time to time shall carry me a long way in the journey of life on which I

am about to embark.

Thank you.

Madhuranga S.H.R.

EG/2012/1986

Department of Electrical and Information Engineering,

University of Ruhuna.

4 | P a g e

Contents Introduction to the Training Establishment. .............................................................8

1.1 Company Profile. .............................................................................................8

1.1.1 Introduction. .............................................................................................8

1.1.2 Vision. ......................................................................................................9

1.1.3 Mission. ....................................................................................................9

1.1.4 History. ...................................................................................................10

1.1.5 Achievements. ........................................................................................10

1.1.6 Objectives ....................................................................................................13

1.2 Organization Structure. ..................................................................................14

1.2.1 Organization Structure of CD&CC. ............................................................14

1.2.2 Organization Structure of Traffic Light System Unit. ................................15

1.2.3 Divisions......................................................................................................16

1.2.4 Services provides by State Development & Construction Corporation. .....17

1.2.5 Strengths of State Development & Construction Corporation. ...................18

1.2.6 Weaknesses of State Development & Construction Corporation and ........19

Suggestions to overcome them. ............................................................................19

1.2.7 Usefulness of State Development & Construction Corporation to the .......20

Society. .................................................................................................................20

Technical Details. .......................................................................................................21

2.1 Introduction to Project. .......................................................................................21

2.2 Introduction to the work site. .............................................................................22

2.3 Traffic light design and Drawing. ......................................................................23

2.4 Writing LADDER program for PLC ..................................................................25

2.4.1 What is PLC? ..............................................................................................25

2.4.2 Ladder programming. ..................................................................................29

2.5 Preparing control unit .........................................................................................36

2.5.1 Solid-State Relay (SSR) ..............................................................................38

2.5.2 Multiplexor box ...........................................................................................38

2.5.3 DC power Supply. .......................................................................................38

2.6 Making structure and wiring. .............................................................................39

2.6.1 3-aspect signal head ....................................................................................39

2.6.2 Red, amber & green count-down ................................................................40

2.6.3 2-aspect signal head with red & green count-down ....................................40

2.6.4 3-aspect right arrow .....................................................................................40

2.6.5 Push button ..................................................................................................41

2.6.6 Camera ........................................................................................................41

5 | P a g e

2.6.7 Loop detector & Frequency counter............................................................42

2.6.8 Fiber to Ethernet converter ..........................................................................43

2.6.9 Router ..........................................................................................................44

2.6.9 Traffic officer on/off switch ........................................................................45

2.7 Maintaining and Repairing .................................................................................45

Management Details ...................................................................................................47

3.1 Management Techniques....................................................................................48

3.1 5S system........................................................................................................48

3.2 Listen, Then Speak Out ..................................................................................48

3.3 Gather the Group ............................................................................................48

3.4 Be Impartial ....................................................................................................49

3.5 Do Not Postpone Conflict Resolution ............................................................49

3.6 Promote Teamwork ........................................................................................49

3.7 Broadcast Praise .............................................................................................49

3.2 Labor Management ............................................................................................50

3.6 Financial Management .......................................................................................51

3.6.1 Valuation of Assets and their Measurement Bases .....................................51

3.6.2 Liabilities and Provisions ............................................................................54

3.6.3 Income Statement ........................................................................................55

3.7 Safety Management ............................................................................................57

Summary and Conclusions ........................................................................................58

4.1 Summary ............................................................................................................58

4.2 Conclusions ........................................................................................................59

References ...................................................................................................................60

6 | P a g e

LIST OF TABLES

2.1 The legend of traffic light drawings…..………………………………. 8

2.2 The basic ladder logic contact symbols……..………………………… 30

7 | P a g e

LIST OF FIGURES

1.1 : SD&CC Logo……………………………………………………………08

1.2 : Organization Structure……………………………………………….…..14

1.3 : TLS unit Organization Structure……………………………………..…..15

2.1 : Map of ongoing projects are located………………………………….....21

2.2 : The traffic light drawing of Vivekananda junction……………………....24

2.3 : Phase arrangement of the Vivekananda junction………………………...26

2.4 : Idec MicroSmart Pentra brick PLC……………………………………... 26

2.5 : Siemens 1200 PLC……………………………………………………….26

2.6 : Parts of Idec MicroSmart Pentra brick PLC……………………………...27

2.7 : Parts of Siemens 1200 PLC……………………………………………....28

2.8 : Module of Idec MicroSmart Pentra brick PLC………………………..….28

2.9 : Module of Siemens 1200 PLC…………………………………………….28

2.10: Siemens LOGO! 8 PLC…………………………………………………...39

2.11: Simple LADDER program……………………………………………..…39

2.12: WindLDR software interface…………………………………………..….35

2.13: TIA portal 13 software interface………………………………………..…35

2.14: Siemens laptop………………………………………………………..…...36

2.15: Control unit……………………………………………………………..…37

2.16: Current indicator………………………………………………………..…37

2.17: MCB, RCB & CB………………………………………………………….37

2.18: SSR that used for LED bulbs………………………………………..... .….37

2.19: Normal relay that used for halogen bulb……………………………...……37

2.20: Multiplexor box…………………………………………………………....37

2.21: DC power Supply……………………………………………………….…39

2.22: Junction & pedestrian traffic lights…………………………………….….39

2.23: 3-aspect signal head…………………………………………………….…39

2.24: Red, amber & green count-down…………………………………………40

2.25: 2-aspect signal head with red & green count-down………………………40

2.26: 3-aspect right arrow……………………………………………………….40

2.27: Push button………………………………………………………………..41

2.28: FLIR’s SafeWalk camera………………………………………………….41

2.29: Analog to digital image converter…………………………………………42

2.30: Loop detector………………………………………………………………42

2.31: Frequency counter…………………………………………………………42

2.32: Fiber to Ethernet converter………………………………………………...43

2.33: Fiber optics cables…………………………………………………………44

2.34: Router……………………………………………………………………...44

2.35: Ethernet cable………………………………………………………………44

2.36: Key switch………………………………………………………………….45

2.37: Remote switch………………………………………………………………45

2.38: Maintaining and Repairing………………………………………………….45

2.39: User login interface of plants management system…………………………46

8 | P a g e

Chapter One

Introduction to the Training Establishment.

1.1 Company Profile.

1.1.1 Introduction.

State Development & Construction

Corporation (SD&CC) falls under the purview of

Ministry of Construction, Engineering Services,

Housing and Common Amenities.

SD&CC plays a major role in the development of Sri Lanka, especially in the

upliftment of Infrastructure Construction. Various major engineering projects in the

fields of Construction such as bridges, roads, highways, dams, irrigation determent

schemes, hydro power tunnels and power houses, water supply and treatment works,

multi storied buildings have been successfully completed by SD&CC. And also

Traffic Light System is the most important projects of SD&CC now. Always they

improve their technologies that have been used in traffic light control systems until

now. Electro-Mechanical works, all type of steel fabrication work, hire of machinery,

repair & maintain all machinery and equipment owned by the corporation.

The Corporation is rated as a Grade One (M1) Contractor under Grading

Scheme conducted by the Institute of Construction Training and Development

(ICTAD), the National Regulating Body of Sri Lanka.

SD&CC is the leading local organization capable of constructing long span

bridges, under design & build basis.

Name of the Enterprise : State Development & Construction

Corporation (SD&CC)

Legal Status of the entity: Government Corporation

Act of Incorporation : Industrial Corporation Act.No. 49 of 1957

Figure 1.1 : SD&CC Logo

9 | P a g e

Year of Incorporation : 1971

Registered Office : No.7, Borupana Road, Ratmalana

Tele. 0112 607560

Internal Audit Division : No. 07, Gregory’s Avenue,Colombo 7

Tele. 0112 – 672196

Concrete Yards : i. Ratmalana Concrete Yard, No.7, Borupana

Rd,Ratmalana

Tele.No. 0112 – 632786

ii. Bopitiya Concrete Yard, Pannala

Tele.No. 037-2288415

iii. Weragantota Concrete Yard, Mahiyanganaya .

Tele.No. 055 – 2257101

iv. Medawachchiya Concrete Yard ,Jaffna Road,

Medawachchiya

Tele.No. 025-3899916

v. Peradeniya Sales Centre

Tele No. 081-2387056

1.1.2 Vision.

To be the best infrastructure development and construction organization,

providing value for money for the Nation.

1.1.3 Mission.

To, assist economic development of the country, by participating in national

infrastructure development and other construction activities and carrying out such

activities to the highest standards of quality and be the market leader in the civil

construction industry and in the production of heavy reinforced and pre-stressed

concrete members in the pre- cast concrete industry.

10 | P a g e

1.1.4 History.

State Development and Construction Corporation was established in 1971 as a

State organization by an extra ordinary gazette notification of 29th March 1971 under

the State Industrial Corporation Act No. 49 of 1957 to undertake heavy civil

engineering construction works.

The turnover of work services was derive from the services rendered

by Central Mechanical Division. The main objective of this division is provide

services to existing project of the Corporation. In addition to that the Traffic

Light Signal Unit ( TLS) also function under the Central Mechanical Division,

which was established in 2005 to install and maintain Traffic Light signal systems

for Road Development Authority. The contribution of this work services to the

turnover of Corporation is 2%. In the beginning they used PIC (Peripheral Interface

Controller) control unit which introduced by the faculty of engineering university of

moratuwa. But at the mean time they replaced their systems by PLCs (Programmable

Logic Controllers) with some changing of the traffic lights wiring. And also they

replaced their all the halogen bulb by LED lights. In 2013, they change from IDEC

PLC to SEIMENCE PLC because of the synchronous purposes. Now they are using

many advance devices for their traffic light systems.

1.1.5 Achievements.

Traffic Light Signal Systems.

SD&CC undertakes maintenance and operation of existing traffic light signal

system and installation of new systems. This new systems has already been

implemented at many road junctions and pedestrian crossing in suburbs of Colombo.

The system has been extend for cities outside Colombo [Katugastota, Nittambuwa,

Kandy and Matara etc.]

11 | P a g e

Hydro Power Tunnels and Power Projects.

SD&CC is capable of handling any type of tunneling work either for hydro power or

Irrigation projects.

Welioya tunnel of 1.25km in length was constructed for Department of

Irrigation.

Tunnel repair works and another works of Pollgolla, Canyon, Bowatena and

Wimalasurendra tunnels.

Canyon Hydro Power Project with an installed capacity of 60 MW was

constructed for Ceylon Electricity Board, with

4,000 meters long D-shaped fully concrete lined Tunnel of 3m

diameter,

Surge chamber & tail race canal,

Power houses, switchyard and other ancillary service structures.

Bridges.

With the construction of over 300 bridges throughout Sri Lanka to its credit,

since its inception, the SD&CC can claim with confidence that it specializes in bridge

building. Almost all the bridges constructed have been concrete structures using

concrete cylinders or concrete piles for foundations, reinforced concrete sub structures

with pre-stressed concrete beams for the decks.

The Road Development Authority (RDA) and the Mahaweli Authority of Sri

Lanka (MASL) and Urban Development Authority (UDA) are the major clients for

whom almost all the bridges have been constructed by SD&CC.

Roads.

SD&CC has undertaken the widening and improvement of existing roads and

the construction of new roads to modern standards for Road Development Authority

(RDA) and Mahaweli Authority of Sri Lanka (MASL). This includes a substantial

quantum of road development in mountain terrain as well.

Access road to Kukule Ganga Hydro Power Project, Roads in Kothmale and

Victoria Power Projects, 50km length of New Kandy Girandurukotte road are some of

the major projects undertaken.

12 | P a g e

Buildings.

SD&CC has to its credit the construction of several single and multi -storied

buildings. Among them are,

Coastal Engineering Laboratory Building project at Katubedda (Lanka

Hydraulic Institute)

The Six-Storied Repair Centre Building for the Sri Lanka Telecom.

Staff quarters and Admin. building & Drawing office for Faculty of

Engineering University of Ruhuna.

Awissawella Bus Park & Town centre.

Irrigation Systems.

In the field of Irrigation, SD & CC has undertaken the construction of wide

range of structures,

- Diversion Dams.

- Anicuts.

- Earth bunds.

- Downstream structures.

Water supply Projects.

SD&CC undertakes the construction of water supply projects, such as water

towers, intakes, treatment plants pipe laying etc.

Improvement to Water Treatment Plant at Ambatale, ADB funded

Anuradhapura water supply projects are some major projects undertaken by SD&CC.

13 | P a g e

1.1.6 Objectives

1. To continue as a self-financing Government Organization.

2. To be a viable and profitable entity and maintain a net profit margin of 10% .

3. To achieve an average turnover growth of 25%

4. To reduce direct and indirect fixed overhead factors to 7% and 8%

respectively.

5. To reduce wastage and losses to less than 5%

6. To build a corporate profile for quality and efficiency in executing civil

& electro –mechanical contracts within the given time frame

7. To maintain a highly motivated and contended workforce by providing

a share of profit to the work force annually and provide necessary

welfare facilities

8. To provide opportunities to Managerial / Engineering/ Technical

personnel to enhance knowledge in modern technology and skills in

construction engineering and managerial fields.

9 To be the market leader in high quality concrete, reinforced concrete

and pre-stressed concrete products for the use of construction

industries.

10 To become the foremost organization in the construction industry and

be one of the leading engineering organizations inthe country.

14 | P a g e

Chairman

General Manager

working Directors

Internal Audit

Board of Directors

Figure 1.2: Organization Structure

1.2 Organization Structure.

1.2.1 Organization Structure of CD&CC.

The objectives of State Development & Construction Corporation (SD&CC)

and the means of attaining these objectives and monitoring the performance

were provided through the corporate governance. Therefore, corporate governance

structures that promote effective identification, monitoring and management of all

material business risks are given priority. Therefore the organization structure of the

State Development & Construction Corporation is divided in to separate designations

according to their works and divisions as shown in bellow.

Finance

Security Personnel &

Administration

Mechanical

Supplies

Design

Planning &

Production

Construction

Performance

Monitoring Unit

15 | P a g e

Mechanical division

Repair & Maintanance unit

Traffic Light System unit

Figure 1.3: TLS unit Organization Structure

1.2.2 Organization Structure of Traffic Light System Unit.

When considering above structure Construction, Design Planning &

Production, Supplies, Personnel & Administration, Performance Monitoring Unit,

Finance and mechanical are divided to another sub organization structures. According

to my industrial training program I was included to mechanical division. Traffic Light

System (TLS) unit is the sub part of the mechanical division. I dialed with this TLS

unit. There for I would like to introduce the organization structure of the TLS unit.

Assistant Electrical

Engineer

Software Designer

& Developer

Chief Electrical

Engineer Secretary

Secretary

PLC

Programmer Electricians

Laborers

16 | P a g e

1.2.3 Divisions.

Construction Division.

This division functions under the Deputy General Manager (Construction). All

the construction sites operate under DGM(C) with the assistance of Chief Engineers

(Construction), who manage the work sites from the area offices. All activities

connected with work sites are coordinated by this division.

The Construction Management Unit, which prepares monthly progress claims,

other extra claims and other financial reports related to construction works attached to

construction division and managed by Chief Engineer (Contracts Management).

Mechanical Division.

The Mechanical Division functions under the Deputy General Manager

(Mechanical). All machinery and equipment owned by the corporation are managed

by this Division. Repair and Maintenance Workshops and Transport Division are

operating under the Mechanical Division. The central workshop is located at

Ratmalana capable of handling all repair and maintenance works and functions under

this division. They undertake,

All type of steel fabrication work

Repair works

Hire of machinery

Electro-Mechanical works

Design & Installation of Traffic Light Signal System.

Designs Planning & Production Division.

This Division is managed by Deputy General Manager (Designs Planning &

Production). Design Office and the Estimates Section responsible for the submission

of tenders, function under this division.

Three Concrete Yards owned by the corporation also managed by

DGM(DP&P) with the assistant of Chief Engineer (Concrete Yards).

17 | P a g e

1.2.4 Services provides by State Development & Construction Corporation.

SD&CC undertakes maintenance and operation of existing traffic light

signal system and installation of new systems.

SD&CC is capable of handling any type of tunneling work either for

hydro power or Irrigation projects.

Power houses, switchyard and other ancillary service.

All type of steel fabrication work.

Hire of machinery.

Electro-Mechanical works.

SD&CC specializes in bridge building.

SD&CC undertakes the construction of Diversion Dams, Anicuts, Earth

bunds, Downstream structures.

SD&CC undertakes the widening and improvement of existing roads

and the construction of new roads.

SD&CC constructs of several single and multi -storied buildings.

SD&CC undertakes the construction of water supply projects, such as

water towers, intakes, treatment plants pipe laying etc.

18 | P a g e

1.2.5 Strengths of State Development & Construction Corporation.

The SC&CC is the main Traffic Lights designer in Sri Lanka. They install

Traffic Lights using new technologies. And also they used advanced devises

as the Seimense 1200 PLC, Safewalk pedestrian camera, Loop detector, Bright

LED colour light & countdown and ect.

They mechanical work shop their own. That work shop planed & make

mechanical structures that want to Traffic light installation and civil

construction.

SD&CC have a large vehicle & machinery strength that want any construction

process and they repair their vehicles & machineries in their mechanical

workshop by themselves.

There are number of Civil engineers, Mechanical engineers and Electrical

engineers work in SD&CC. They have the ability to achieve success of any

complex project.

High educated persons are working at administrative level and management

level. Therefore, the supervision is well in the cooperation.

More than 500 trained labourer, technicians and supervises are working at

SD&CC having good experience.

Road Development Authority (RDA), Mahaweli Authority of Sri Lanka

(MASL) and International Construction Consortium (Pvt) Ltd (ICC) usually

work with SD&CC.

SD&CC has concrete yards at Ratmalana, Bopitiya, Weragantota,

Medawachchiya. It manufactures all types of pre stressed post tensioned

beams, electrical transmission poles RCC spun pipes, bridge components,

hollow blocks and other pre-cast concrete products in their yards.

19 | P a g e

1.2.6 Weaknesses of State Development & Construction Corporation and

Suggestions to overcome them.

LED count down, LED running man or normal man, LED lights are imported

from china. LED count down, LED running man or normal man circuit are

complex. But LED lights can be made in Sri Lanka. In the beginning they

install Sri Lankan halogen Light System. Some of them are working until now.

But the brightness of the old system is less than the LED lights. If there is an

electronic engineer with trained labourers, they will do experiment for

electronic parts. Otherwise they should get technical support from an

engineering faculty or other electronic service provider in Sri Lanka. If they

can produce their LED colour lights by themself, the wastage of money will be

stopped.

Now they use galvanized new structure to install the Traffic Lights that

imported from china. Five years ago, a casting engineer worked in SD&CC

and there are all the things that want for casting. If they can fill that vacancy,

the wastage of money will be stopped.

At the mean time SD&CC change from IDEC PLC to SEIMENCE PLC.

SEIMENCE PLCs are more cost than the IDEC PLCs. SEIMENCE is the

German company and their Sri Lankan dealer is the biggest automation

company in Sri Lanka. SD&CC pays about Rs.80,000 for one

PLS(SEIMENCE 1200 PLS). But it real price is around Rs.40,000. Some

Indian dealers supply this PLS to that price. Because of the programing

service and the warranty SD&CC have to buy PLCs from that company. It’s

better they can find low cost and trust another dealer.

In world there are more advance Traffic Light systems are using. Those

systems can be control from the one control unit. But Sri Lankan system runs

according to previous downloaded pregame. It can’t be change when it is

running. But SD&CC is getting steps to solve that problem.

20 | P a g e

1.2.7 Usefulness of State Development & Construction Corporation to the

Society.

In the earlier traffic police faced big troubles when controlling the traffic jam.

And also drivers, pedestrians had to waste their time in the road. Sometimes they have

to die on way. Therefore SD&CC introduce and improve Traffic Light Systems by

associating with Road Development Authority (RDA). Their systems are install in

Colombo city, Galle road, Negombo, Nugegoda, Kandy, Matara, at all the highway

entrance and etc. Traffic police officers always thank for the SD&CC, because they

know what kind of traffic will happen, if they didn’t introduce those Traffic Light

Systems.

And also SD&CC is doing major construction part of Sri Lanka joining with

the Road Development Authority (RDA), Mahaweli Authority of Sri Lanka (MASL),

International Construction Consortium (Pvt) Ltd (ICC) and etc. They construct road,

bridges, buildings, tunneling work either for hydro power or Irrigation projects, water

towers, intakes, treatment plants pipe, diversion dams, anicuts, earth bunds,

downstream structures.

21 | P a g e

Figure 2.1: Map of ongoing projects are located

Chapter Two

Technical Details.

2.1 Introduction to Project.

When I went to

the DC&C they were

doing very many

projects. Their projects

mainly situated around

Colombo. All the Traffic

Lights of Galle road from

Panadura to Colombo is

installed by the SD&CC.

Ramakrishna junction,

Vivekanada junction and

W.A. Silva junction in

Wellawatte were installed

when I went

there. The second day of my training, I had opportunity to participate for system-on,

at above mention Ramakrishna & Vivekananda junctions. And also third day, they

switch on the system at W.A. Silva junction. But that system didn’t work correctly. In

the mean time of my training, they found the error and again switch on the system.

I had opportunity to deal with many ongoing projects in Kolluptiya,

Bouddhaloka road and some pedestrian light on Galle road. And also I had to

participate for some trouble shootings. I went to many junctions & pedestrian lights

that shown in covered area of the above map. Sometimes I had to stay at one junction

in whole day, because we had to change phase times and cycle time according to

traffic jam changing.

Basically SD&CC installs Traffic Light for junctions and pedestrian crossing.

Road Development Authority (RDA) planes the phase arrangement of the road and it

is provided to the SD&CC. Then SD&CC have to,

Prepare the light arrangement design a drawing.

Write a LADDER program for PLC.

22 | P a g e

Send the PLC input & output pin configuration and head-counter details to the

TLS work shop (shop six). Then the control unit is made in there.

Give the wiring arrangement to a supper (normally all the supervisors are

electricians) to set tours and lay the under-ground wires. Then they went to the

location with labours and set the lights and wire. If there is any

synchronization they should lay the fiber-optic cable.

Install the system and connect the wires to the output of SSR (Solid State

Relay). If there is any synchronization, they have to use Fiber to Ethernet

converter and small router for switching.

Download the program to PLC and check whether it’s working correctly.

After above mention process the project is completed. But every maintenance

are done by SD&CC. Sometimes they have to add some extra devices according to

the requirement of the RDA. Some of them are,

Pedestrian camera.

Pedestrian push button.

Loop detectors.

Remote or external system on/off switch for traffic officers.

2.2 Introduction to the work site.

Project Details.

Project Name : Traffic Lights and Pedestrian colour light system installation

and synchronization.

Client : Ministry of transformation.

Contractor : International Construction Consortium (Pvt) Ltd (ICC).

Sub-Contractor : State Development & Construction Corporation (SD&CC).

Consultant : Road Development Authority (RDA).

Engineer : Chief Electrical Engineer Mr. P.S.R Perera.

Electrical Engineer M.A.W.S Udayarathne.

Software Designer & Developer Mr. D.M.N. Kanchana.

23 | P a g e

There are two different work site as,

Inside work site.

Outside work site.

Inside work site.

This is situated in SD&CC, Rathmalana. It is called as TLS shop or shop-6.

Control units making, Lights repairing, making structures and testing are done here.

And also it is the store of Traffic Light unit.

Outside work site.

This outside work sites are situated at all the Traffic Light Systems which are

installed by them. Sometimes it will be working system or installing system. If it is

working system, normally they will go here to upload or download a program and

repairing (Ex: replace SSR or Traffic Lights). If it is installing system, normally they

doing their works at night. Then they have to dig pit, drain or lay wire or install the

tower.

2.3 Traffic light design and Drawing.

Traffic light design and Drawing is very important to install the Traffic light and

repairing. All the details are shown in this drawing. After planning, engineers give

this drawing to the supervisors. Then they install the Traffic Lights according to the

drawing. Supervisors are trained to read the drawings. By referring the drawing, we

can get knowledge about following things;

Phase arrangement.

Number of heads & countdown that want.

Dimension of the junction.

Duct line and gulley.

24 | P a g e

To read a Traffic Light drawing the legend is very important. The legend of above

figure is not very clear. So the sample legend is shown in below.

Symbols Description

DRAW PIT (DP)

DUCT LINE

3 ASPECT SIGNAL HEAD

2 ASPECT SIGNAL HEAD WITH RED & GREEN

COUNTDOWN

RED &GREEN COUNTDOWN

3 ASPECT RIGHT ARROW

Figure 2.2: The traffic light drawing of Vivekananda junction.

Table 2.1: The legend of traffic light drawings.

25 | P a g e

In the Vivekananda junction there are two phase arrangement as shown in

below. The junction runs according to that 2-phase arrangement always

First phase arrangement:

Phase-1, phase-2 and pedestrian are opened. Its mean all the vehicles are

released which are going to Colombo & Rathmalana. And also pedestrian are released

to cross the Vivekananda road. (Some vehicles are waiting to go Colombo &

Rathmalana on the Vivekananda road)

Second phase arrangement:

Phase-3 and phase-4 are opened. Its mean all the vehicles are released which

are going to Colombo & Rathmalana from Vivekananda road. (At that time another

vehicles are waiting to go Colombo and Rathmalna at the Vivekananda junction)

2.4 Writing LADDER program for PLC

2.4.1 What is PLC?

PLCs (Programmable Logic Controllers) is an industrial computer control

system that continuously monitors the state of input devices and makes decisions

based upon a custom program to control the state of output devices. The biggest

benefit in using a PLC is the ability to change and replicate the operation or process

while collecting and communicating vital information. Another benefit is ability to

increase the inputs and outputs by using modules.

1

4 2 3

Figure 2.3: Phase arrangement of the Vivekananda junction.

26 | P a g e

First SD&CC used Idec MicroSmart Pentra brick PLC. Because of the

synchronization now they mainly use Siemens 1200 PLC. But Idec PLCs are used for

small junction. It available with 12V DC, 24V DC and 100-240V AC power, you can

choose from 10, 16 and 24 I/O configurations. The 10 I/O CPU is equipped with six

DC inputs and four relay outputs, while the 16 I/O CPU is equipped with nine DC

inputs and seven relay outputs. The 24 I/O CPU is equipped with 14 DC inputs and

ten relay outputs. The 24 I/O CPU (24V DC and 100-240V AC models) can also be

expanded with a maximum of four functional or discreet expansion modules. With

this latest model, you

can configure the

MicroSmart Pentra

PLC for remote

monitoring and

control. Using

WindLDR software,

you can remotely

monitor or update the

PLC programs

without having to be

near the PLC.

Figure 2.4: Idec MicroSmart Pentra brick PLC.

Figure 2.5: Siemens 1200 PLC.

Figure 2.6: Parts of Idec MicroSmart Pentra brick PLC.

27 | P a g e

Now the SD&CC is using Siemens 1200 PLC for their new projects. The main

purpose of using this PLC is synchronization.

The new modular SIMATIC S7-1200 controller is at the core of our new

offering for simple but highly precise automation tasks. The SIMATIC S7-1200

controller is modular and compact, versatile, a secure INVESTMENT, and is

perfectly suited to a whole range of applications.

The S7-1200 CPUs with Safety Integrated handle both standard and safety-

related tasks. A compact design with integrated IO, communication interfaces that

meet the highest industry requirements and a range of powerful integrated

technological functions make this controller an integral part of a comprehensive

automation solution.

The compact SIMATIC S7-1200 system consists of different CPU

performance classes: CPU 1211C, CPU 1212C, CPU 1214C, CPU 1215C and CPU

1217C and two failsafe versions CPU 1214FC and CPU 1215FC. Each of these may

be expanded according to the machine requirements. The S7-1200 CPUs can be

expanded with up to three communication modules (CM) and eight signal modules

(SM). Signal modules and signal boards can be integrated in order to expand the

digital or analog IOs without affecting the physical size of the controller.

Figure 2.7 : Parts of Siemens 1200 PLC.

28 | P a g e

Modules are used to increase inputs and outputs of the PLCs. But there is a limit for

connecting modules. (EX: 11 modules can be connected to the Siemens 1200 PLC)

Siemens 1200 is very advance PLC. So, its all features are not useful for Traffic Light

project of SD&CC. They use only synchronization. Therefore they plane to change

for Siemens LOGO! 8 PLC.

The successful Siemens logic

module has launched the next

generation. This new module

accommodates virtually every

demand of customers with

simplified handling, a new display,

and full communication options via

Ethernet. And the web server

application makes everything very

simple. A communications module

provides for remote communications via cellular phone network, rounding out the

range of new ways to use LOGO!

Figure 2.8 : Module of Idec MicroSmart

Pentra brick PLC.

Figure 2.9 : Module of Siemens 1200 PLC.

Figure 2.10 : Siemens LOGO! 8 PLC.

29 | P a g e

2.4.2 Ladder programming.

Ladder logic is widely used to program PLCs, where sequential control of a

process or manufacturing operation is required. Ladder logic is useful for simple but

critical control systems or for reworking old hardwired relay circuits. As

programmable logic controllers became more sophisticated it has also been used in

very complex automation systems. Often the ladder logic program is used in

conjunction with an HMI program operating on a computer workstation.

The motivation for representing sequential control logic in a ladder diagram

was to allow factory engineers and technicians to develop software without additional

training to learn a language such as FORTRAN or other general purpose computer

language. Development, and maintenance, was simplified because of the resemblance

to familiar relay hardware systems. Implementations of ladder logic have

characteristics, such as sequential execution and support for control flow features, that

make the analogy to hardware somewhat inaccurate. This argument has become less

relevant given that most ladder logic programmers have a software background in

more conventional programming languages.

Manufacturers of programmable logic controllers generally also provide

associated ladder logic programming systems. Typically the ladder logic languages

from two manufacturers will not be completely compatible; ladder logic is better

thought of as a set of closely related programming languages rather than one

language. Even different models of programmable controllers within the same family

may have different ladder notation such that programs cannot be seamlessly

interchanged between models.

Ladder logic can be thought of as a rule-based language rather than a

procedural language. A "rung" in the ladder represents a rule. When implemented

with relays and other electromechanical devices, the various rules "execute"

simultaneously and immediately. When implemented in a programmable logic

controller, the rules are typically executed sequentially by software, in a continuous

loop (scan). By executing the loop fast enough, typically many times per second, the

effect of simultaneous and immediate execution is achieved, if considering intervals

greater than the "scan time" required to execute all the rungs of the program. Proper

use of programmable controllers requires understanding the limitations of the

execution order of rungs.

30 | P a g e

Some LADDER logic signals are shown in below that use in WindLDR;

Table 2.2: The basic ladder logic contact symbols

Ladder

symbol

Description

Normally open (NO) contact. Passes power (on) if *** is on (closed)

Normally closed (NC) contact. Passes power (on) if *** is off (open).

Positive transition sensing contact. If the state of *** changes from off

to on, this contact passes power for only one scan (until rung is scanned

again).

Negative transition sensing contact. If the state of *** changes from on

to off, this contact passes power for only one scan (until rung is scanned

again).

Table 2.3: The basic ladder logic coil (output) symbols

Ladder

symbol

Description

Output or coil. If any left-to-right rung path passes power, the ***

output is energized (on). If there is no continuous left-to-right rung

path passing power, the *** output is de-energized (off).

Negated coil. If any left-to-right rung path passes power, the ***

output is de-energized (off). If there is no continuous left-to-right rung

path passing power, the *** output is energized (on).

Set coil. If any rung path passes power, *** is energized and remains

energized, even when no rung path passes power.

Reset coil. If any rung path passes power, *** is de-energized and

remains de-energized, even when no rung path passes power.

Positive transition sensing coil. If conditions before this coil change

from off to on, *** is turned on for one scan

31 | P a g e

Negative transition sensing coil. If conditions before this coil change

from on to off, *** is turned on for one scan.

Retentive memory coil. Like the ordinary coil, except the value of ***

is retained even when the PLC is stopped or power fails.

Set retentive memory coil. Like the set coil, except the value of *** is

retained even when the PLC is stopped or power fails.

Reset retentive memory coil. Like the reset coil, except the value of

*** is retained even when the PLC is stopped or power fails.

Some advance LADDER symbols is shown in below that use in WindLDR.

Following blocks are very important in writing Traffic Light program.

Timer

Four types of timers are available;

TML - 1-sec countdown timer,

TIM - 100-msec countdown timer,

TMH - 10-msec countdown timer and

TMS - 1-msec countdown timer.

Each timer must be allocated to a unique number T0 through T255.

Off-Delay Timer

Four types of time-down off-delay timers are available;

TMLO - 1-sec off-delay timer,

TIMO - 100-ms off-delay timer,

TMHO - 10-ms off-delay timer and

TMSO - 1-ms off-delay timer.

A total of 256 on- and off-delay timers can be programmed in a user program

for any type of CPU module. Each timer must be allocated to a unique number T0

through T255.

32 | P a g e

The CNT (Counter) Instruction

Three types of counters are available;

CDP - dual-pulse reversible counter,

CUD - up/down selection reversible counter and

CNT - adding (up) counters.

A total of 32(10-point type) or 100(other types) counters can be programmed.

Each counter must be allocated to a unique number 0 through 255.

CNTD, CDPD, and CUDD (Double-Word Counter)

Three types of double-word counters are available;

CNTD - adding (up) counter,

CDPD - dual-pulse reversible counter and

CUDD - up/down selection reversible counter.

A total of 128 double-word counters can be programmed in a user program for

any type of CPU module. Each double-word counter uses 2 consecutive operands

starting with the allocated operand, which can be C0 through C254. Once used in a

user program, counters cannot be used in any other counter instructions.

Counter Comparison

When a counter comparison instruction is programmed, two addresses are

required. The circuit for a counter comparison instruction must be programmed in the

following order: the CC= or CCe instruction; a counter number C0 through C255,

followed by a preset value to compare from 0 to 65535.

Data Register Comparison

When a data register comparison instruction is programmed, two addresses are

required. The circuit for a data register comparison instruction must be programmed

in the following order: the DC= or DC>= instruction, a data register number D0

through D1999 (all CPU modules) or D2000 through D7999 and D10000 through

D49999 (slim type CPU modules), followed by a preset value to compare from 0 to

65535.

33 | P a g e

Shift Register

The SFR (Forward) and

SFRN (Reverse) Shift Register Instructions

The shift register consists of a total of 256 bits which are allocated to R0

through R255. Any number of available bits can be selected to form a train of bits

which store on or off status. The on/off data of constituent bits is shifted in the

forward direction (forward shift register) or in the reverse direction (reverse shift

register) when a pulse input is turned on.

Master Control Set (MCS) and Master Control Reset (MCR)

The MCS (master control set) instruction is usually used in combination with

the MCR (master control reset) instruction. The MCS instruction can also be used

with the END instruction, instead of the MCR instruction

Jump (JMP) and Jump End (JEND)

The JMP (jump) instruction is usually used in combination with the JEND

(jump end) instruction. At the end of a program, the JMP instruction can also be used

with the END instruction, instead of the JEND instruction.

End

The END instruction is always required at the end of a program; however, it is

not necessary to program the END instruction after the last programmed instruction.

34 | P a g e

Figure 2.11: Simple LADDER program.

Figure 2.12: WindLDR software interface.

35 | P a g e

WindLDR software is introduced by the Idec to program their PLCs. As well as the

TIA portal 13 software is introduce by the Siemens to program their 1200 PLS. TIA

portal 13 software is very complex than the WindLDR software and it is not provided

as free software. And also Siemens softwares are running well in their laptops only.

But Siemens laptops are mainly use for industrial purposes. So it is very difficult to

learn their softwares.

Figure 2.13: TIA portal 13 software interface.

Figure 2.14: Siemens laptop.

36 | P a g e

2.5 Preparing control unit

Engineers send PLC input & output pin configuration and head-counter details

to the TLS work shop (shop six). Then the system unit is made in there. A PLC (Idec

or Siemens PLC), Relays (SSR or normal relays), A Power supply, Multiplexor

boxes, A MCB, A RCB, Indicators and three pin plug bases are installed as shown in

bellow. After that all the devises are wired using red, green and yellow wires. The

special devises of fiber to Ethernet converters and a router are installed by the special

electrician.

Figure 2.15: Control unit.

37 | P a g e

Figure 2.20: Multiplexor box.

Figure 2.18: SSR that used for

LED bulbs.

Figure 2.17: MCB, RCB & CB.

Figure 2.16: Current indicator.

Figure 2.19: Normal relay that used for

halogen bulb.

Figure 2.21: DC power Supply.

38 | P a g e

2.5.1 Solid-State Relay (SSR)

A solid-state relay (SSR) is an electronic switching device that switches on or

off when a small external voltage is applied across its control terminals. SSRs consist

of a sensor which responds to an appropriate input (control signal), a solid-state

electronic switching device which switches power to the load circuitry, and a coupling

mechanism to enable the control signal to activate this switch without mechanical

parts. The relay may be designed to switch either AC or DC to the load. It serves the

same function as an electromechanical relay, but has no moving parts.

Packaged solid-state relays use power semiconductor devices such as

thyristors and transistors, to switch currents up to around a hundred amperes. Solid-

state relays have fast switching speeds compared with electromechanical relays, and

have no physical contacts to wear out. Application of solid-state relays must consider

their lower ability to withstand momentary overload, compared with

electromechanical contacts, and their higher "on" state resistance. Unlike an

electromechanical relay, a solid-state relay provides only limited switching

arrangements

2.5.2 Multiplexor box

Multiplexors box requires for traffic light count-down. SD&CC uses a

Multiplexors box that is produced by China Company specially for them. It has 2

input (A & B), 10 output (D1 to D10) and 2 terminal for power supply.

2.5.3 DC power Supply.

PLC and modules require 24 DC voltage to give output. Therefore every

control units have a DC power supply. For an example they use Siemens SITOP

PSU100L. The power supplies required following features;

● Narrow design

● Good efficiency

● Can be connected in parallel

● Cooling through natural convection

39 | P a g e

2.6 Making structure and wiring.

According to supplied drawing supervisors guided the labours to install the

traffic light tower and hang 3 aspect signal head, red, amber & green count-down, 2

aspect signal head with red & green count-down, 3 aspect right arrow, push button

and camera. After that they set loop detector if it needs. Then install the control unit.

Finally wires and fiber optics are laid through drain and wired all the devices. If

there is a fiber optics connection, fiber to Ethernet converter and router will be

connected by special electrician.

2.6.1 3-aspect signal head

According to the PLC

output signal 3 aspect signal

head’s sequence is changed.

Red : Stop

Red & Amber : Ready

Amber : Ready

Green : Go

This sequence is repeating in cycle time of the PLC. Considering situation of the

junction or pedestrian crossing red, amber and green times are changed. Those times

are not constant in the whole time.

Figure 2.23: 3-aspect signal head.

Figure 2.22: Junction & pedestrian traffic lights.

40 | P a g e

2.6.2 Red, amber & green count-down

The count-down

sequence is also same to

the 3-aspect signal head’s

sequence. But another two

outputs of the PLC are

used to give the signals to

it. Count-down can’t read this two output signal. Therefore those outputs are gave to

the multiplexor box and multiplexor outputs are connected with the red, amber &

green count-down.

2.6.3 2-aspect signal head with red & green count-down

2-aspect signal head with red &

green count-down are used for pedestrian

crossing. Only two output of the PLC is

enough for the 2-aspect signal head and red

& green count-down. There is a special

circuit in the red & green count-down. In the

first two cycles, count-down doesn’t display

anything. But after two cycles later, it

automatically counts the time and displays it.

2.6.4 3-aspect right arrow

3-aspect right arrow is same to the 3-

aspect signal head. Only different between

them is arrow shape lights. It is used in

junction to show L-turn.

Figure 2.24: Red, amber & green count-down.

Figure 2.25: 2-aspect signal head with red & green count-down.

Figure 2.26: 3-aspect right arrow.

41 | P a g e

Figure 2.28: FLIR’s SafeWalk camera.

2.6.5 Push button

Pedestrian pushbuttons are

electronic buttons used by pedestrians to

change traffic signal timing to

accommodate pedestrian street

crossings. Pushbuttons may be needed

at some crossings, but their use should

be minimized. As traffic signals become

more complex pedestrian pushbuttons

are needed. If buttons exist, pedestrians

must push them to get enough time to

cross the street. Standard pushbuttons

often result in longer waits to cross the

street, especially if the pedestrian fails to push the button. Sometimes, pedestrians

push the button and go away. Therefore SD&CC uses a pedestrian camera to check

whether pedestrians are still waiting or not.

2.6.6 Camera

Pedestrian presence sensors are a

safer and more efficient alternative to

push buttons. Research has shown that

70% of pedestrians will cross the road

without waiting for the green signal after

pushing the button. This results in

unnecessary interruption of traffic flows

and in more traffic congestion. In

contrast, pedestrian detection will drop

the green call when pedestrians are no

longer waiting to cross. While

pedestrians are crossing, pedestrian detection will extend the red light signal for

vehicles to enable a safe passage. FLIR’s SafeWalk camera is used by SD&CC. But it

is an analog camera and its output can’t give to the PLC directly. So that they have to

use analog to digital image converter. That device is shown in below.

Figure 2.27: Push button.

42 | P a g e

Figure 2.29: Analog to digital image converter.

Figure 2.31: Frequency counter. Figure 2.30: Loop detector.

2.6.7 Loop detector & Frequency counter.

An induction or inductive loop is an electromagnetic communication or

detection system which uses a moving magnet to induce an electrical current in a

nearby wire. Induction loops are used for transmission and reception of

communication signals, or for detection of metal objects in metal detectors or vehicle

presence indicators.

Vehicle detection loops, called inductive-loop traffic detectors, can detect

vehicles passing or arriving at a certain point, for instance approaching a traffic light

or in motorway traffic. An insulated, electrically conducting loop is installed in the

43 | P a g e

Figure 2.32: Fiber to Ethernet converter.

pavement. The electronics unit transmits energy into the wire loops at frequencies

between 10 kHz to 200 kHz, depending on the model. The inductive-loop system

behaves as a tuned electrical circuit in which the loop wire and lead-in cable are the

inductive elements. When a vehicle passes over the loop or is stopped within the loop,

the vehicle induces eddy currents in the wire loops, which decrease their inductance.

The decreased inductance actuates the electronics unit output relay or solid-state

optically isolated output, which sends a pulse to the traffic signal controller signifying

the passage or presence of a vehicle.

A frequency counter is an electronic instrument, or component of one, that is

used for measuring frequency. Frequency is defined as the number of events of a

particular sort occurring in a set period of time. Frequency counters usually measure

the number of oscillations or pulses per second in a repetitive electronic signal.

SD&CC uses Ultra II D-TEK Plug In Style Vehicle Loop Detector with following

features;

ULTRAMETER™ (displays optimum sensitivity setting / diagnostic aid)

Frequency count/reset switch

10 sensitivity settings

Loop diagnostics

4 operating frequencies

Lightning and surge protection

Frequency counter

Fail safe Operation

CE compliant

Optional accessories include PR-Loop

2.6.8 Fiber to Ethernet converter

A technology that uses glass (or plastic) threads

(fibers) to transmit data. A fiber optic cable consists of a

bundle of glass threads, each of which is capable of

transmitting messages modulated onto light waves.

Fiber optics has several advantages over traditional

metal communications lines.

44 | P a g e

Figure 2.33: Fiber optics cables.

Figure 2.34: Router.

Figure 2.35: Ethernet cable.

In synchronization, normally there are two signals come to the one control unit from

front and back control units. Those signals are passed through the fiber optics cable.

But that signals can’t access directly to the PLCs. So that fiber to Ethernet converter is

required. Therefore two fiber to Ethernet converters(MMF 100BASE-EX) are used in

one control unit.

2.6.9 Router

A router is a device that forwards data

packets along networks. A router is

connected to at least two networks,

commonly two LANs or WANs or a LAN

and its ISP's network. Routers are located at

gateways, the places where two or more

networks connect.

In here they have to use a router for

switching purpose. Because, two Ethernet

cables comes to the PLC and it easy to download and upload program by connecting

router and computer using another Ethernet cable.

45 | P a g e

Figure 2.36: Key switch. Figure 2.37: Remote switch.

Figure 2.38: Maintaining and Repairing.

2.6.9 Traffic officer on/off switch

In special occasion, traffic officers have to switch off the control unit and control the

traffic by themself. For example;

When VIP vehicles coming

If there is any picketing or political meeting on the road

In New Year seasons and etc.

2.7 Maintaining and Repairing

46 | P a g e

Figure 2.39: User login interface of plants management system.

All the Traffic Lights are maintained and repaired by SD&CC that installed by them.

Changing PLC program or camera program.

Repairing control unit.

Repairing and replacing heads & counters.

Do all the electrical repairing.

Specially, one team (One supervisor with four labours) goes inspections daily.

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

The Chief Electrical Engineer, Mr.P.S.D. Perera gave me a special

project me to make a web base plants management system. They want

to update all the plant details in to one table, after updating plants

details site wise. Therefore I made a database using html, php &

Mysql. Finally they really appreciate my project.

47 | P a g e

Chapter Three

Management Details The objectives of State Development & Construction Corporation (SD&CC)

and the means of attaining these objectives and monitoring the performance

were provided through the corporate governance. Therefore, corporate governance

structures that promote effective identification, monitoring and management of all

material business risks are given priority.

SD&CC, being a fully Govt. owned institution operate under the purview of

the Ministry of Construction & Engineering Services and the General Treasury. Board

of Directors are directly accountable to the Government through the line

ministry. Therefore the Board of Directors and the senior management of SD&CC

have a duty to ensure that the organization governed and operated in the best

interest of the Corporation and its stake holders in full compliance with the

regulatory frame work.

In terms of the constitution , Parliament has full control of public

finance and therefore public enterprises are subject to Parliamentary control.

The cabinet of ministers is responsible for taking decisions relating to public

enterprises. The General Treasury is responsible for financial and operational

disciplines of the public corporations. For this purpose, the General Treasury issues

regulations, rules, codes, guidelines and directives through circulars to ensure that

the board of directors properly discharge their responsibilities with regard to the

economic efficiency and effectiveness.

Except for the General Treasury representative Director, the other

appointments to the Board of Directors including head of the institutions of Govt.

Corporations are made by the secretary to the line ministry based on the

recommendation of the minister in charge under which the enterprise falls. The

General Treasury, being the shareholder, appoints one director.

The Board of Directors had no personnel interest which conflicted with the

interest of the Corporation. The activities of the Corporation were conducted to build

the Corporation to more financially and operationally viable entity in the

construction industry.

48 | P a g e

3.1 Management Techniques

3.1 5S system

SD&CC uses 5S system very effectively to do their all the works very efficiently. The

whole SD&CC premises are arranged according to the 5S system. 5S is workplace

management where the work area and workplace are organized and ritualized to

minimize the loss of time and the use of movement.

5S is much more than “a place for everything and everything in its place”. 5S

comprises five principles to make people highly efficient and effective in their doing

work.

Sort -Keep near you only what you regularly use

Straighten -Find exactly what you need to use in less than 30 seconds

Shine -Have your workplace and equipment ready for immediate use

Standardize -Everyone does each job in the same way and is challenged to

improve it

Sustain -Everyone does their part to foster a safe, efficient and effective

workplace

3.2 Listen, Then Speak Out

Believe it or not, just listening to an employee’s issue is the first and most

important step in resolving conflict. They simply listen to all parties involved to

completely understand the nature of conflict, and then start troubleshooting solutions.

3.3 Gather the Group

As a leader, they arrange a meeting with all involved parties to discuss the

issue. Give everyone a chance to speak; this is a good opportunity to hear all sides and

gain a full understanding of the conflict. Having a group meeting may also expedite a

resolution that will satisfy everyone.

49 | P a g e

3.4 Be Impartial

Don’t take sides! In a leadership position, they don’t display any sort of

opinion that favors one person over another. If they are partial towards one person, try

to access the situation from all sides to come up with a fair and reasonable solution.

3.5 Do Not Postpone Conflict Resolution

Address the conflict immediately. Otherwise, the situation could escalate and

could affect employee performance. Just make sure not to address the situation too

quickly or without careful consideration, as their decision will directly affect the

demeanor and performance of their staff.

3.6 Promote Teamwork

Encouragement and motivation are powerful. Remind their staff of successful

projects that required teamwork to complete. This is one of the most effective conflict

resolution techniques and will really make the employees think about the importance

of working in a team.

3.7 Broadcast Praise

As stated above, the power of encouragement and motivation can be

multiplied when it is spread to recognize those who are modeling the teamwork and

cooperation that is desired within any conflict. So they try to give suitable models in

these instances because behavior modeling can be risky if there are elements in the

model that are undesirable.

50 | P a g e

3.2 Labor Management

HUMAN RESOURCES

The foremost resource that controls all the other resources in the

Organization is the human resources. The Prime Strength of our Organization is

the Staff who possess wide experience, capabilities, and skills related to our

objectives and targets of the Corporation.

The Human Resources Department played a vital role to achieve the ISO

2008. In achieving the ISO 2008 the Human Resources Division gained varied

experience & all Methods & Systems were developed to the present trend.

The following programs were worked out during the year 2015 in order to

develop the knowledge, skills, and to maintain standards to keep the Employees

satisfied in order to motivate the human resources towards the fulfillment of the

objectives of the Organization.

3.2.1 Staff Promotions

During the year 2015, 41 persons from all grades of Officers and

Workers were given promotions further motivating them in order to achieve the

objectives of the Organization.

3.2.2 Training and Development

A large number of Staff representing various sections were given training to

develop their knowledge and talents. Special mention be made about the Overseas

training given to several Employees during the year.

Steps have been taken to offer Extensive training to the Personnel directed to

us by External Institution to be trained in various fields, which is done as a

contribution towards the General Development of the Country.

51 | P a g e

3.2.3 Staff Welfare

Steps were taken to continue the Medical Insurance Scheme for the

Employees sponsored by the Organization. A compensation Insurance Scheme have

been introduced confirming the security of the work force. All bonus payments were

paid to the Staff of the Corporation in April 2015.

3.2.4 Rewards to Employees

Employees who have completed 25 years of continuous service in the

Corporation were felicitated with a gold Sovereign and a Souvenir as a token

of appreciation at the 38th Anniversary Celebrations of the Corporation held at

the Ministry Auditorium under the distinguish patronage of the Hon. Minister in

Charge.

3.6 Financial Management

3.6.1 Valuation of Assets and their Measurement Bases

3.6.1.1 Inventories

Inventories are valued at the lower of cost and net realizable value, after

making due allowances for obsolete and slow moving items. Net realizable value is

the price at which inventories can be sold in the ordinary course of business less the

estimated cost of completion of the sale.

3.6.1.2 Trade Debtors and Other Receivables

Trade debtors are stated at the amounts they are estimated to realize net of

provisions for bad and doubtful debtors. Other receivables and dues are recognized at

cost less provision for bad and doubtful receivables.

52 | P a g e

3.6.1.3 Cash and Cash Equivalents

Cash and cash equivalents are defined as cash in hand, demand deposits and

short term highly liquid investments, readily convertible to known amounts of

cash and subject to insignificant risk of changes in value.

3.6.1.4 Property, Plant and Equipment

a) Cost

Property, Plant & Equipment is recorded at cost less accumulated depreciation.

b) Cost and Valuation

All items of Property, Plant & Equipment are initially recorded at cost.

Where items of Property, Plant and Equipment are subsequently revalued, the entire

class of such assets is revalued. Revaluations are made with sufficient regularity

to ensure that their carrying amounts do not differ materially from their fair values

as at the balance sheet date.

c) Depreciation

The provision for depreciation is calculated by using the straight line method

on the cost or valuation of all property, plant and equipment other than freehold land,

in order to write off such amounts over the following estimated useful lives by equal

installments.

Land Over prolonged of Period

Buildings Over 20 Years

Office Equipment Over 10 Years

Plant & Machinery Over 10 Years

Motor vehicles Over 05 Years

Other Assets Over 10 Years

53 | P a g e

3.6.1.5 Leases

a) Finance Leases

Property, plant and equipment on finance leases, which effectively

transfer to the Corporation substantially all of the risk and benefits incidental to

ownership of the leased item are capitalized at their cash price and disclosed as

property, plant and equipment and depreciated over the period the Corporation is

expected to benefit from the use of the leased assets.

b) Operating Leases

Leases where the lesser effectively retains substantially all the risks and

benefits of ownership over the leased term are classified as operating leases. Rentals

paid under operating leases are recognized as an expense in the income statement on

a straight-line basis over the lease term.

3.6.1.6 Investments

a) Current Investments

Current investments are stated at lower of cost and market value determined

on an aggregate portfolio basis. The cost of an investment is the cost of acquisition

inclusive of brokerages, fees, duties and bank fees.

b) Associate Company Investments

Investments in associate companies are accounted for on the equity

method, whereby the share of profit of the associates attributable to the company is

accounted for as income and the value of the investment (which was initially

recognized at cost) adjusted by a like amount.

c) Related Parties

Corporation has entered into a Joint Venture with Mass Trust Holdings to

form a Company, Fujima State Corporation (Pvt.) Ltd. during the last year SD&CC

owns 51% of authorized share capital of this Company and Ms. Mass Trust Holdings

owns 49% of authorized share capital. Mr. B.M.S.Samarasekara, Chairman SD&CC

is a Director of Fujima Sate Corporation.

54 | P a g e

3.6.2 Liabilities and Provisions

3.6.2.1 Retirement Benefit Obligations

a) Defined Benefit Plan – Gratuity

Gratuity is a Defined Benefit Plan. The Corporation is liable to pay gratuity in

terms of the relevant statute. In order to meet this liability, a provision is carried

forward in the balance sheet, equivalent to an amount calculated based on a half

month’s salary of the last month of the financial year of all employees for each

completed year of service, commencing from the first year of service. The

resulting difference between brought forward provision at the beginning of a year

and the carried forward provision at the end of a year is dealt with in the income

statement.

3.6.2.2 Bad debts Provision

a) Provision for Debtors

For Debtors over 05 years are provided 100% unlessthere is a possibility of recovery.

For balance debtors provision have been made in the following manner taking with

the account the age analysis, moments and the current position there in.

Age (years) Rate

0-1 --

1-2 2.5%

2-3 25%

3-4 30%

4-5 50%

Over 5 years 100%

b) General Provision for Other Debtors

40% is provided from the other category of debtors which have no transaction for

over more than one year.

55 | P a g e

c) Recognition of work-in- progress

Direct operating Cost in respect of bills not certified and a portion of direct cost

on under certified bills decided by the construction division have been recognized as

work-in progress.

3.6.3 Income Statement

Identified losses on construction contracts.

3.6.3.1 Revenue Recognition

Revenue is recognized to the extent that it is probable that the economic benefits

will flow to the Corporation and the revenue and associated costs incurred or to

be incurred can be reliably measured. Revenue is measured at the fair value of

the consideration received or receivable net of trade discounts and sales taxes. The

following specific criteria are used for the purpose of recognition of revenue.

a) Construction Income

The revenue from certified bills as at the balance sheet date is recognized as

income in full.

b) Identified losses on Construction Contracts

The Corporation policy is to identify the profit or loss on contracts on certified

bills. Therefore profit or loss identified in the financial statements as and when they

are incurred irrespective of the percentage of completion therein.

c). Sale of Goods – Pre Cast Yards

Revenue from sale of goods is recognized when the significant risks and

rewards of ownership of the goods have passed to buyer; with the Corporation

retaining neither continuing managerial involvement to the degree usually

associated with ownership, nor effective control over the goods sold.

56 | P a g e

d). Interest

Interest Income is recognized as the interest accrues (taking into account the

effective yield on the asset) unless collectability is in doubt.

e). Rental income

Rental income is recognized on accrual basis.

f). Others

Other income is recognized on an accrual basis. Net Gains and losses of a revenue

nature on the disposal of property, plant & equipment and other non-current assets

including investments have been accounted for in the income statement, having

deducted from proceeds on disposal, the carrying amount of the assets and related

selling expenses. On disposal of revalued property, plant and equipment, amount

remaining in Revaluation Reserve relating to that asset is transferred directly to

Accumulated Profit.

Expenditure Recognition

Expenses are recognized in the income statement on the basis of a direct association

between the cost incurred and the earning of specific items of income. All

expenditure incurred in the running of the business and in maintaining the property,

plant & equipment in a state of efficiency has been charged to income in arriving at

the profit for the year.

3.6.3.2 Contingent Liabilities

Corporation has issued bonds & guarantees of Rs. 459Mn to its clients for

projects executed as at the Balance Sheet date. There is no any possibility to lodge

claims against these bonds issued.

57 | P a g e

3.7 Safety Management

Safety of the workers in m organization is very critical point. As I observed

during my training period SD&CC management has provided their workers safety

equipments they needed during their working hours such as ladders, helmets, glosses,

belts, jackets and etc. But unfortunately very few workers use them while they are

working. This is very displeasing situation because there can be bad consequences

because of the carelessness of the workers of their own safety. So according to my

knowledge I think management should give their attention more to have programs to

emphasize the safety of workers by not only giving them equipment but also

encouraging workers to use them as well.

SD&CC has a good security system for the protection of the company. If a

visitor comes to the SD&CC office he or she has to leave his ID card at the reception

and should give the specific place and person he or she needs to meet. Then a

permission card only to enter the relevant area is issued for the visitor and this

permission card must be worn inside the SD&CC premises by the visitor.

58 | P a g e

Chapter Four

Summary and Conclusions

4.1 Summary

During 12 weeks of my training experience in State Development &

Construction Corporation, I was able to involve with site work, laboratory work as

well as the administrative and office work. I had to go for site more than two days per

week. Some days we are staying at a junction or pedestrian crossing in whole day. It

was very hard work, but it was very interesting and gave knowledge.

As well as I had good practical knowledge in the TLS workshop (shop six). In

here I was dealing with Siemens and Idec ladder programming. Mechatronic

programmer really helps me to understand the ladder programs. And also I could deal

with PLS, relays, count-down camera and etc. SafeWalk camera programming is very

interesting and there was small image processing part. I had opportunity to make a

control unit in TLS work shop.

Sometimes they asked me to guide two or three labours in the site and TLS

workshop. And also they asked me to prepare a web base plant’s management system.

So I have already prepared it using html, php and Mysql database. They really

appreciated my plant’s management system. So my industrial training period was

remarkable and very important period in my life. The knowledge I got there, not only

about technical aspects but also about human resource management was a great

advantage for my life

59 | P a g e

4.2 Conclusions

At the University, we were taught many theories and given chances to do

several practical, experiments and tests to understand the concepts of Electrical,

Electronic, Software & Telecommunication. But it was truly a remarkable

opportunity to have my first training experience in a leading company as State

Development & Construction Corporation. During this period I was able to gather

vary rare experiences. I was able b to gain new insights and more comprehensive

understanding about the real electronic & electrical industry beyond the theoretical

background.

Those experiences lead me to change my attitudes about working environment

and build good carrier in future. Apart from technical knowledge, the soft skills that

we were exposed to will be invaluable for our future lives. Working with staff of

different statuses, collectively working as a team, handling customers, documentation

and reporting, punctuality, adjusting to the office culture are some of the skills we

developed during these three months.

Finally I can conclude that by undergoing the industrial training program

offered, at the largest Traffic Light service provider and primitive constructor in the

country, have exposed me with many aspects and latest technological trends in the

growing electronic & electrical industry and these valuable experiences have built me

an interest to continue my future career in electronic industry.

I personally believe that State Development & Construction Corporation is

one of the best training place for training Engineer who is in the field of Traffic

Lights. SD&CC provides a special training program.

The three month time of my training at State Development & Construction

Corporation was a very beneficial time for me as an Engineering undergraduate. It is

my firm belief that the experience and knowledge I gathered from this training will be

very useful for me to serve my country as a professional Engineer.

60 | P a g e

References

State Development & Construction Corporation :

http://www.sdcc.lk/

Siemens web site :

http://w3.siemens.com/mcms/programmable-logic-

controller/en/pages/default.aspx

Idec web site :

http://www.idec.com/gben/products/Catalogs/PLCs/MicroSmartPentra/overvie

w.html

FLIR traffic camera web site :

http://www.flir.com/traffic/display/?id=61995

Wikipedia :

http://en.wikipedia.org/wiki/Solid-state_relay