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BAHIR DAR UNIVERSITY

BAHIR DAR INSTITUTE OF TECHNOLOGY


FACULTY OF ELECTRICAL AND COMPUTER ENGINERING

Industry Internship report


Hosting Company
Amhara Metal Industry and Machine Technology Development

No. Name of interns: ID

1. Habteselassie Mekuriaw 1011265


2. Kefale Shita 1011250
3. Henok Lealem 1011263
4. Addisu Muche 1011232

Advisor: Mr. Kassaye G. and Destaw A.

February, 2022
Bahir Dar, Ethiopia
INTERSHIP IN AMIHARA METAL INDUSTRY AND MACHINE
TECHNOLOGY DEVELOPMET ENTERPRISE
2014 E.C

Declaration

We are 4th year Electrical and computer Engineering student in Bahir Dar Institute of
Technology /BIT/, and We have been undertaken our internship experience in Amhara metal
industry and machine technology development enterprise (AMIMTDE) for a period of four
months from August 2021- November 2021 under the guidance of Mr. Kassaye G. and Mr.
Destaw A.,academic advisor and Mr. Tesfamariam company advisor.

Student name: ID No Date Signature


Habteselassie Mekuriaw 1011265 ________ ________
Addisu Muche 1011232 ________ ________
Henoke LeaLem 1011263 ________ ________
Kefale Shita 1011250 ________ ________

Academic advisor: Date: Signature


Mr. Kassaye G. _____________ __________
Mr. Destaw A. ______________ ____________

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BAHIR DAR INSTITUTE OF TECHNOLOGY
INTERSHIP IN AMIHARA METAL INDUSTRY AND MACHINE
TECHNOLOGY DEVELOPMET ENTERPRISE
2014 E.C

Acknowledgment

First of all, we would like to thank the almighty God for his unforgettable help in all direction.
We express our thankfulness to God for his blessing and guidance throughout our entire training.
We would like to express our profound to Amhara metal industry and machine technology
development enterprise which is willing to accept our internship program, for valuable guidance
and providing necessary facilities and source during this internship program.
We would like to thanks for Bahir Dar Institute of technology for providing such kind of
opportunity for students to apply their understanding in practical knowledge and improve
theoretical knowledge. Next to this we give great altitude for our advisor for Mr. Kassaye G. and
Mr. Destaw A., academic advisor and Mr. Tesfamariam company advisor.

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INTERSHIP IN AMIHARA METAL INDUSTRY AND MACHINE
TECHNOLOGY DEVELOPMET ENTERPRISE
2014 E.C

Table of Contents

Declaration ....................................................................................................................................... i
Acknowledgment............................................................................................................................. ii
List of Figures ................................................................................Error! Bookmark not defined.
List of Acronyms ........................................................................................................................... vii
Executive Summary .................................................................................................................. viii

CHAPTER ONE 1........................................................................................................................... 1


1 BACKGROUND OF THE COMPANY ...................................................................................... 1
1.1 Introduction............................................................................................................................ 1

1.1.1 Background of the company ........................................................................................... 1

1.2 Mission of the company......................................................................................................... 3

1.3 Vision of the company ........................................................................................................... 3

1.4 Objectives of the enterprise ................................................................................................... 3

1.5 Values of the company .......................................................................................................... 3

1.6 Organizational structure of the company ............................................................................... 4

1.7 Work flow .............................................................................................................................. 5

1.8 Key Stake holder of AMIMTDE ........................................................................................... 6

2 Overall Internship Experience ...................................................................................................... 7


2.1 Objectives of the internship ................................................................................................... 7

2.1.1 General objective ............................................................................................................ 7

2.1.2 Specific objectives .......................................................................................................... 7

2.2 How did we get the company?............................................................................................... 7

2.3 Overall System Components and Operations ........................................................................ 8

2.3.1 Automatic transfer switching (ATS) .............................................................................. 8


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BAHIR DAR INSTITUTE OF TECHNOLOGY
INTERSHIP IN AMIHARA METAL INDUSTRY AND MACHINE
TECHNOLOGY DEVELOPMET ENTERPRISE
2014 E.C

2.3.2 Selection modes .............................................................................................................. 9

2.3.3 Air conditioning system ................................................................................................ 10

2.4 Distribution power transformer ........................................................................................... 11

2.4.1 Some parts of a transformer .......................................................................................... 12

2.4.2 Working principle of the transformer ........................................................................... 17

2.5 Transformer Maintenance and Testing Workshop .............................................................. 19

2.5.1 DC Resistance test ........................................................................................................ 19

2.5.2 Transformer turn ratio test ............................................................................................ 19

2.5.3 Transformer Winding Machine .................................................................................... 20

2.5.4 Vacuum Drying machine .............................................................................................. 20

2.5.5 Insulation Resistance/Megger Test of Transformer ..................................................... 21

2.5.6 Oil treatment machine................................................................................................... 22

2.5.7 Transformer testing machine ........................................................................................ 22

2.6 Major duties of the Intern .................................................................................................... 23

2.7 Challenges faced and measures ........................................................................................... 23

2.7.1 Challenges..................................................................................................................... 23

2.7.2 Measures taken to overcome the challenges ................................................................. 24

3 Benefits Gained from the Internship .......................................................................................... 25


3.1 Upgrading theoretical knowledge and Improving Practical skills ....................................... 25

3.2 Improving team playing skills ............................................................................................. 25

3.3 Improving interpersonal communication skills ................................................................... 26

3.4 Leadership skills .................................................................................................................. 26

3.5 Over All Achievements of the Intern ................................................................................... 27

CHAPTER FOUR 4 ...................................................................................................................... 28


4 PROJECT AND CONTRIBUTION .......................................................................................... 28
4.1 Introduction.......................................................................................................................... 28

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BAHIR DAR INSTITUTE OF TECHNOLOGY
INTERSHIP IN AMIHARA METAL INDUSTRY AND MACHINE
TECHNOLOGY DEVELOPMET ENTERPRISE
2014 E.C

4.1.1 Project title: Power factor improvement ....................................................................... 28

4.1.2 Background of study ..................................................................................................... 28

4.2 Problem statement ............................................................................................................... 29

4.3 Objective .............................................................................................................................. 29

4.3.1 General objective .......................................................................................................... 29

4.3.2 Specific objective .......................................................................................................... 30

4.4 Material and methodology ................................................................................................... 30

4.4.1 Material used ................................................................................................................ 30

4.4.2 Methodology ................................................................................................................. 31

4.5 Contribution ......................................................................................................................... 32

4.6 conclusion ............................................................................................................................ 32

CHAPTER FIVE ....................................................................................................................... 33

5 .CONCULSION AND RECOMMENDATIONS ...................................................................... 33


5.1 CONCULSION.................................................................................................................... 33

5.2 RECOMMENDATIONS ..................................................................................................... 33

5.2.1 Recommendation for the Company .............................................................................. 33

5.2.2 Recommendation for Faculty ....................................................................................... 35

5.2.3 Recommendation for Industrial Linkage ...................................................................... 35

5.3 REFERENCE ...................................................................................................................... 36

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BAHIR DAR INSTITUTE OF TECHNOLOGY
INTERSHIP IN AMIHARA METAL INDUSTRY AND MACHINE
TECHNOLOGY DEVELOPMET ENTERPRISE
2014 E.C

List of Figures
Figure 1.1Organizational structure of the company ........................................................................ 4
Figure 1.2 Work flow of company .................................................................................................. 5
Figure 2.1 Automatic transfers switching ........................................................................................ 8
Figure 2.2 ATS control panel .......................................................................................................... 9
Figure 2.3 Different parts of the transformer ................................................................................. 11
Figure 2.4 Internal Parts of MV Transformer ................................................................................ 12
Figure 2.5 Tape changer of transformer ........................................................................................ 14
Figure 2.6 Transformer coils windings .......................................................................................... 14
Figure 2.7 Transformer magnetic core .......................................................................................... 15
Figure 2.8 Transformer type in shape ............................................................................................ 16
Figure 2.9 front side view internal part ......................................................................................... 16
Figure 2.10 DC Winding resistance test ........................................................................................ 19
Figure 2.11 Tern ratio tester .......................................................................................................... 20
Figure 2.12 Horizontal winding machine ...................................................................................... 20
Figure 2.13 Vacuum drying oven .................................................................................................. 21
Figure 2.14 . Transformer insulation tester ................................................................................... 22
Figure 2.15 Oil treatment machine ................................................................................................ 22
Figure 2.16 . Transformer Test bench ........................................................................................... 23
Figure 4.1 Automatic power factor improvement ........................................................................ 31

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BAHIR DAR INSTITUTE OF TECHNOLOGY
INTERSHIP IN AMIHARA METAL INDUSTRY AND MACHINE
TECHNOLOGY DEVELOPMET ENTERPRISE
2014 E.C

List of Acronyms

AC Alternative Current
AMIMTDE Amhara Metal Industry and Machine Technology
Development Enterprise
DC Direct Current
EMF Electro Motive Force
HV High Voltage
LED Light Emitting Diode
LV Low Voltage
NWR North West Region
UIL University Industrial Linkage

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BAHIR DAR INSTITUTE OF TECHNOLOGY
INTERSHIP IN AMIHARA METAL INDUSTRY AND MACHINE
TECHNOLOGY DEVELOPMET ENTERPRISE
2014 E.C

Executive Summary

This paper is a report of an internship program at Amhara Metal Industry and Machine
Technology Development Enterprise (AMIMTDE). It is prepared as one of the compulsory
inputs for the proper execution of the internship program.
This report is considered as the way for intern students to prepare or ready ourselves for real
practical world both in technical and social perspectives and also it describes selection of a
problem that is facing during internship and solves such problems.

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BAHIR DAR INSTITUTE OF TECHNOLOGY
INTERSHIP IN AMIHARA METAL INDUSTRY AND MACHINE
TECHNOLOGY DEVELOPMET ENTERPRISE
2014 E.C

CHAPTER ONE

1 BACKGROUND OF THE COMPANY

1.1 Introduction
Manufacturing industry in Ethiopia has been started in 1920s with a simple processing
technology that produces agriculture-based products. However, the manufacturing sector is still
infant, dominantly semi-processing, and performs at a minimal capacity. The manufacturing
sector has persistently faced high production cost, severely constrained supply and poor-quality
raw materials and technology, both mainly imported, witnessing little improvements in the main
areas of challenges over the years. It has neither transformed itself to high technology
processing nor competitive in the international market.

1.1.1 Background of the company

The fixed assets are located in Amhara Region at two places, namely at Bahir Dar and
Kombolcha City. The assets found at Bahir Dar and Kombolcha production center consist of
production office buildings, machinery, motor, office furniture and equipment. Both centers are
coordinated by main office named as Amhara metal Industry and machine development
enterprise. The Kombolcha production center is located about 450 kilometers from the center of
Bahir Dar. Whereas, the one and the main office is sited at the center of Bahir Dar city.
The center is established in 1985 E.C by the name of Bahir Dar Rural Technology Promotion
Center with the aim of multiplying and popularizing agricultural implements around mandate
area. It was organized in Small-scale agricultural implements, rural industry development and
rural energy development team.
After 1996 E.C, the center has been re-organized with the objective of supporting the
sustainability of the agricultural development in the Region through design, testing and
promoting agricultural implements. This time it was rearranged in prototype design & studies
and production & maintenance team.
In 1999, the name of the center is changed to Bahir Dar Agriculture mechanization and Food
Science research center and started to conduct research on generating/selecting, developing,
adopting and promoting appropriate agricultural mechanization technologies at the regional
level. Bahir Dar Agricultural Mechanization & Food Science Research Center, (BAM&FSRC)

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BAHIR DAR INSTITUTE OF TECHNOLOGY
INTERSHIP IN AMIHARA METAL INDUSTRY AND MACHINE
TECHNOLOGY DEVELOPMET ENTERPRISE
2014 E.C

undertook problem oriented agro-ecology based research on pre-harvest and irrigation


technologies, post-harvest handling and processing technologies, animal husbandry
technologies And alternative energy technologies for developments, testing and popularization
of need based farm implement and machinery to increase productivity of land and labor through
timelines of operations efficient use of inputs, improvement in quality of produce and safety
and comfort of farmers, and reduce drudgery. The major activities encompass; Conducting
and/or promoting research and develop in appropriate mechanization, processing and alternative
energy technologies to increase agricultural production and productivity of the region,
collecting processing and disseminating information in appropriate technologies and food
utilization to the needs of the farmers.
The sector's contribution for the national GDP is stagnated at less than 5% for the last 20 years.
Existing technology transfer mechanisms are poorly institutionalized. As a result, about 80% of
the national exports are agricultural, while manufacturing accounts about 10%, which in terms
of value is only about 0.5% of the total export.
For this reason, it has been found necessary for the Amhara National Regional State to create a
capacity and develop inspiration in the metal and machine technology development. The
Amhara Metal Industry & Machine Technology Development Enterprise is a governmental
institution which was transformed by regulation No. 127/2014 under the provision of article 58,
sub article 7 of the revised national constitution of the Amhara national regional state. This
enables to achieve the development goals of the industrial sector in the region. With the view to
support the development, it has been found necessary to accelerate the industrialization
transformation of the region by getting rid of investment limitations, inadequacy of
productivity, least technological capability, poor supply of production inputs, weak
commercialization confronted on the major manufacturing industry components and thereby
filling the gap of the market therein.
In addition to this the enterprise is making a great research and analysis on socio economic on
solar system like solar street light, solar operated pump and other others. Finally, in 2008 E.C.
the name of the center is changed in to Amhara Metal Industry and Machine Technology
Enterprise (AMIMTDE) and started to conduct research on generating/selecting, developing,
adopting and promoting appropriate machine technologies at the regional level. (From un
published documents of the company). For this report the data is conducted in AMIMITDE at
Bahir Dar branch.

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INTERSHIP IN AMIHARA METAL INDUSTRY AND MACHINE
TECHNOLOGY DEVELOPMET ENTERPRISE
2014 E.C

1.2 Mission of the company


The mission of the AMIMTDE is to become one of the ten premier best technology institutions
in the Africans in 2020 E.C.

1.3 Vision of the company


The vision of AMIMTDE is to contribute for production of quality machine that are used for
both the technology and agriculture and becoming competitive in the world.

1.4 Objectives of the enterprise


The General objective of the enterprise is to full fill the gaps of Agricultural technologies
encountered the small folder farmers for increasing production and productivity of the
Agricultural products.

1.5 Values of the company


• We are passionate about our customer
• Our employees are the heart of our business
• We are committed to deliver exceptional values
• Profitability is the core of our business
• We believe in working together as team and as partner
• We never stop learning and growing
• We care about the environment.

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BAHIR DAR INSTITUTE OF TECHNOLOGY
INTERSHIP IN AMIHARA METAL INDUSTRY AND MACHINE
TECHNOLOGY DEVELOPMET ENTERPRISE
2014 E.C

1.6 Organizational structure of the company


General Manager Secretary
Auditor
Fabrication/subsidiary
Association manager
Law service

Vice general manager Vice general manager


Secretary
Secretary

Technology Production & Quality Sales, finance & Resource


development & market transferring control & Administration Supporting
Market planning Process manager Measurement Process manager
Process manager Process
Manager Human power development
& administration supporting
process manager
Socio-economic Metals industry &
research sub machine work sub
process coordinator process Plan following &
information
Agriculture & Foundry & woods Technology supporting
technology design work sub process Process manager
sub process coordinator
coordinator
Electrical and
electronics sub
Industry &
process
technology design
sub process
manager Assembly and
finishing work sub
process
Market planning
sub process
coordinator

Figure 1.1Organizational structure of the company

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BAHIR DAR INSTITUTE OF TECHNOLOGY
INTERSHIP IN AMIHARA METAL INDUSTRY AND MACHINE
TECHNOLOGY DEVELOPMET ENTERPRISE
2014 E.C

1.7 Work flow

Figure 1.2 Work flow of company

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BAHIR DAR INSTITUTE OF TECHNOLOGY
INTERSHIP IN AMIHARA METAL INDUSTRY AND MACHINE
TECHNOLOGY DEVELOPMET ENTERPRISE
2014 E.C

1.8 Key Stake holder of AMIMTDE

The main stakeholder of AMIMTDE is the Amhara Regional Government, which is the owner
of the corporation, the employees and customers. The owner of the AMIMTDE is the Amhara
Regional Government itself. AMIMTDE is the big company that control and monitor the region
Agricultural technology production and supply, Food processing equipment production and
supply and Construction equipment production and supply as a whole. The major customers of
AMIMTDE are householders, different companies and schools. In addition, governmental and
non-governmental organizations, industries, small scale enterprises and business institutes are
customers and beneficiaries of AMIMTDE. The corporation in general provides service to the
public.

Product of the company

Development Enterprise was established to meet the gap of technology requirement among
Manufacturing Industry, Agriculture Sector, Micro and Small enterprise in terms of product and
service. Currently the company produce different product based on reverse engineering
techniques. Such techniques are important for developing country to produce different spare
part and machine components. The current main product of the company is:
➢ Car parking and shade

➢ Pipe bender

➢ Manual bar cuter

➢ Hand puller winch with self-locking without wire rope

➢ Screw type lift table truck without hydraulic pump

➢ Thresher machine.

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BAHIR DAR INSTITUTE OF TECHNOLOGY
INTERSHIP IN AMIHARA METAL INDUSTRY AND MACHINE
TECHNOLOGY DEVELOPMET ENTERPRISE
2014 E.C

CHAPTER TWO 2

2 Overall Internship Experience


2.1 Objectives of the internship
2.1.1 General objective
To upgrade the theoretical knowledge and to relate our theoretical knowledge with the practical
skills. It fills the gap between what we have learnt and what is on real life ground with the
guidance of the supervisors. It also creates ease for the opportunity of future job employment as
it increases confidence and work ethics in addition to practical knowledge. It also increases skills
in management and communication.

2.1.2 Specific objectives


➢ Internship students will develop skills and techniques directly applicable to their
careers.
➢ Internships will provide students the opportunity to develop attitudes conducive to
effective interpersonal relationships
➢ Internships will provide students with an in-depth knowledge of the formal
functional activities of a participating organization.
➢ Internship programs will enhance advancement possibilities of graduates.
In general, an internship program is thought of as a program which "bridges the gap" between
the academic environment and a future work environment. Many employers prefer students
who have previous work experience and the Internship provides that. Students that participate in
an internship are generally more confident and more qualified when seeking future employment

2.2 How did we get the company?

In the first day we get the Manager of the company and then he takes the letter that we take
from our industrial leakage. In the second day the manager has given us an adviser Mr. Addisu
who control and guide us. He gives us orientation or description on:

• Work Ethics

• What we should have to do and working and working time

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BAHIR DAR INSTITUTE OF TECHNOLOGY
INTERSHIP IN AMIHARA METAL INDUSTRY AND MACHINE
TECHNOLOGY DEVELOPMET ENTERPRISE
2014 E.C

• Introduce with the shop mate (shop mates)

• The working rooms (Those are maintenance room, drying room and testing room).

• Introduce the Engineering methods, tools and techniques

• Safety issue we should have to take while doing Machines (winding, oil treatment,
welding, drying and integrated test machine).

2.3 Overall System Components and Operations

As we indicated in the above, we devote most of our time in power and maintenance sections.
Work that we done in this section starts from Automatic transfer switching (ATS), Air
conditioning system and distribution transformers.

2.3.1 Automatic transfer switching (ATS)

As the society develops, people required better power supply such as two power sources even
three power sources to keep continuous power supply. This will need a device to transfer
between two power sources and three power sources.

Figure 2.1 Automatic transfers switching

Two power sources transferring

ATS comprises of transfer switch, board and circuit, and enclose. It automatic can carry out
transfer to keep one input power supply: While Mains available, it’s on the Main end for power

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BAHIR DAR INSTITUTE OF TECHNOLOGY
INTERSHIP IN AMIHARA METAL INDUSTRY AND MACHINE
TECHNOLOGY DEVELOPMET ENTERPRISE
2014 E.C

supply; While Mains fail or under desired value the sensors send signals to start the generator
then, it will transfer to generator end for power supply. While Mains recover, it will return to
Main end for power supply. Mains and generator will not supply power at the same time.

Control panel detect mains voltage, generator voltage, the voltage on the emergence of unusual
conditions. The realization of the generating units can automatically start and shutdown.

The controller has communication port which match with the communication interface module.
The relative software can display the whole parameters measured and state information; it also
can set various parameters. It enables to obtain more information which can’t get from panel.

Figure 2.2 ATS control panel

2.3.2 Selection modes


AUTO (Automatic mode)
When Main power is available the controller detects and main power will take the load. But when
main power became abnormal (any voltage below or above setting) the controller or the board
detects and send signal to start up generator. As result, Generator starts up and sets up normal
voltage. After the delay, switch will transfer to generator end for power supply and then
generator takes the load. When Mains recovers: after the delay, switch will transfer to Main end
for power supply main power takes the load.

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BAHIR DAR INSTITUTE OF TECHNOLOGY
INTERSHIP IN AMIHARA METAL INDUSTRY AND MACHINE
TECHNOLOGY DEVELOPMET ENTERPRISE
2014 E.C

Manual mode

Manual operation is used in case of switches and control system failure to insure power supply.
You can choose the close direction through “SW1” and “SW2” if the voltage for Mains and
Generator resource are normal.
Test mode

Switch only sends generator startup signal without actual transferring, and Mains is still
supplying power to load. In this situation, generators can startup without taking load. When put
switch back to “AUTO”, generator will stop immediately.

2.3.3 Air conditioning system

There is enormous amount of heat due to working different electrical equipment and
environment conditions. Therefore, appropriate air conditioning system is essential for proper
functioning of all the system of network elements. For all air conditioning systems, the principle
remains the same where by the heat is removed from one area and replaced with chilled dry air
and the hot air is expelled, normally to the outside atmosphere, and sometimes the reverse.
Every air conditioner has a compressor inside it. It works to compress and pump the refrigerant
gas. Compression of refrigerant produces heat. To dissipate this heat, compressed refrigerant is
pumped to the condenser coils where a fan blows the heat out to outer atmosphere. During the
process, refrigerant takes the liquid form. This liquid refrigerant is pumped towards expansion
valve. Expansion valve releases the appropriate amount of refrigerant to evaporator (cooling
coils) where liquefied refrigerant takes gaseous form. Conversion from liquid to gaseous state
due to expansion produces chillness because energy is absorbed from the surrounding. Air when
passes through fins that is, attached to coils, gets cooled and blown to the room.
Refrigerants are substances used by air conditioners to transfer heat and create a cooling
effect. Air-conditioning systems use specially formulated refrigerants designed to change
state at specific temperatures providing optimum cooling. Portables use a refrigerant called
R-22 or HCFC-22. HCFC stands for hydro chlorofluorocarbon.
This is currently the most common refrigerant used by air-conditioning systems.

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BAHIR DAR INSTITUTE OF TECHNOLOGY
INTERSHIP IN AMIHARA METAL INDUSTRY AND MACHINE
TECHNOLOGY DEVELOPMET ENTERPRISE
2014 E.C

2.4 Distribution power transformer


A distribution transformer is a transformer that provides the final voltage transformation in the
electric power distribution system, stepping down the voltage used in the distribution lines to
the level used by the customer. Transformer can operate 24 hours/day, 365 days/year and have
very long lifetimes. Energy consumption during its service life is the dominant factor in their
life cycle assessment. Practical efficient transformer made AC power distribution feasible by
using Distribution transformers. No matter what the shape or size, a transformers purpose
remains the same: transforming electrical power from one value to another.
Step down Transformer that installed in sites of North West Region Amhara National Regional
State Metal Industry and Machine Technology Development Enterprise reduce from 15000 KV
or 33000 KV power lines (EEU) to 380V. There is an inlet and outlet hole (opening) in the
powerhouse for the lines to come in and out respectively. There is Conductor buried under
ground for earthling purpose. An HV terminal comes in while LV terminal gets out

Figure 2.3 Different parts of the transformer

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BAHIR DAR INSTITUTE OF TECHNOLOGY
INTERSHIP IN AMIHARA METAL INDUSTRY AND MACHINE
TECHNOLOGY DEVELOPMET ENTERPRISE
2014 E.C

Figure 2.4 Internal Parts of MV Transformer

2.4.1 Some parts of a transformer


Conservator
It is a big cylindrical tube located on the upper position of a transformer and connected to the
main thank, which is completely filled with oil, through pipe. It is partially filled with oil. When
the temperature of the transformer increases, the oil inside it expands to conservator and vice
versa. It allows a room for oil expansion and contraction.

Breather (silica gel)


They are small cylindrical device placed in the vent pipes of conservators. It dries the air
entering the conservator as volume of oil contracts on the transformer cooling. It uses the
moisture absorbing properties of silica gel crystals. These crystals need replacement when it
becomes saturated with moisture. Replacement is indicated by a change in color of the crystals
from blue to pink. These breathers also have an oil cup fitted with, so that the dust particles get
settled in the cup.

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BAHIR DAR INSTITUTE OF TECHNOLOGY
INTERSHIP IN AMIHARA METAL INDUSTRY AND MACHINE
TECHNOLOGY DEVELOPMET ENTERPRISE
2014 E.C

Oil level indicator


It is used to show the oil level in the transformer. This is an ordinary part situated on the side of
the conservator for proper oil checking oil Tank wants a specific amount of oil.

Radiator
Basically, used for the cooling by the Means of natural air. These are used for cooling of the
transformer oil. Radiators are used in a transformer to cool the transformer oil through natural
air or forced air flowing in these Radiator fins.

Drain valve
This valve is used for taking damaged Oil from the oil tank for the proper oil collection this
Valve is situated under the oil tank.

Bushing
Bushing is an insulating device which covers the conducting material. A typical bushing design
has a 'conductor', (usually of copper or aluminum and of other conductive materials),
surrounded by insulation, except for the terminal ends. This design has to ensure that the
electrical strength of the insulated material is able to withstand the penetrating 'electrical energy'
passing through the conductor, via any highly stressed areas. A fixing device will also be
attached to the insulation to hold it in its location.

Tape changer of transformer


It is a small number of additional turns fitted on the primary winding, such that by switching the
incoming supply to one of the additional set of turns, a change in the voltage ratio is achieved in
proportional to the additional turns. It is used for regulation of the output voltage to required
levels.
This is normally achieved by changing the ratios of the transformers on the system by altering
the number of turns in the primary winding of the transformer. The voltage regulator helps to
maintain balance between the power output and the required output level. The principle of
automatic voltage regulation involves the process of maintaining the voltage flow at a specified
level at all times.

There are voltage power surges that may be caused by unanticipated conditions, such as
lightning or power failures and unless the electrical equipment has an automatic voltage
regulator, the power surges to the equipment could easily damage that equipment when power
is turned off and on.

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BAHIR DAR INSTITUTE OF TECHNOLOGY
INTERSHIP IN AMIHARA METAL INDUSTRY AND MACHINE
TECHNOLOGY DEVELOPMET ENTERPRISE
2014 E.C

Figure 2.5 Tape changer of transformer

Coils/winding

Where incoming alternate current (through primary winding) generates magnetic flux, which in
turn develop a magnetic field feeding back a secondary winding.

Figure 2.6 Transformer coils windings

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BAHIR DAR INSTITUTE OF TECHNOLOGY
INTERSHIP IN AMIHARA METAL INDUSTRY AND MACHINE
TECHNOLOGY DEVELOPMET ENTERPRISE
2014 E.C

Magnetic core

Allowing transfer of magnetic field generated by primary winding to secondary winding by


principle of magnetic induction and used to provide a controlled path for the magnetic flux
generated in the transformer. The core is generally not a solid bar of steel, rather a construction
of many thin laminated steel sheets or layers. This construction is used to help eliminate and
reduce heating.

Figure 2.7 Transformer magnetic core

Transformers generally have two types depending on the type of core it uses: Core Type and
Shell Type. These types are distinguished from each other by the manner in which the primary
and secondary coils are place around the steel core.
• Core type - the winding’s surround the laminated core.
• Shell type -the windings are surrounded by the laminated core.

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BAHIR DAR INSTITUTE OF TECHNOLOGY
INTERSHIP IN AMIHARA METAL INDUSTRY AND MACHINE
TECHNOLOGY DEVELOPMET ENTERPRISE
2014 E.C

Figure 2.8 Transformer type in shape

Figure 2.9 front side view internal part

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BAHIR DAR INSTITUTE OF TECHNOLOGY
INTERSHIP IN AMIHARA METAL INDUSTRY AND MACHINE
TECHNOLOGY DEVELOPMET ENTERPRISE
2014 E.C

Tank

Serving as a mechanical package to protect inside parts, as a holding vessel for transformer oil
used for cooling and insulation and bushing (plus auxiliary equipment where applicable).

2.4.2 Working principle of the transformer


A power transformer is a static electrical device that transfers energy by inductive coupling
between its winding circuits. A varying current in the primary winding creates a varying
magnetic flux in the transformer's core and thus a varying magnetic flux through the secondary
winding. This varying magnetic flux induces a varying electromotive force (EMF) or voltage in
the secondary winding.
It is important to remember that transformers do not generate electrical power; they transfer
electrical power from one AC circuit to another using magnetic coupling without changing the
frequency. The ratio between the numbers of actual turns of wire in each coil is the key in
determining the type of transformer and what the output voltage will be. The ratio between
output voltage and input voltage is the same as the ratio of the number of turns between the two
windings. A transformers output voltage is greater than the input voltage if the secondary
winding has more turns of wire than the primary winding. The output voltage is stepped up, and
considered to be a "step-up transformer". If the secondary winding has fewer turns than the
primary winding, the output voltage is lower. This is a "step-down transformer". The
relationship between the input voltage and output voltage, and the input current and the output
current are given by two simple equations.

Transformer cooling systems


It is essential to control the temperature within permissible limit to ensure the long life of
transformer by reducing thermal degradation of its insulation system. The transformer oil is

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BAHIR DAR INSTITUTE OF TECHNOLOGY
INTERSHIP IN AMIHARA METAL INDUSTRY AND MACHINE
TECHNOLOGY DEVELOPMET ENTERPRISE
2014 E.C

stable at high temperature and has excellent electrical insulating properties. The oil helps cool
the transformer. Because it also provides part of electrical insulation between internal live parts,
Transformer oil must remain stable at high temperatures for an extended period. To improve
cooling of these distribution transformers, the oil-filled tank may have external radiators
through which the oil circulates by natural convection.

Liquid-filled transformers, most often used by electric utilities, have several efficiency
performances advantage over dry-type transformers. Liquid-filled transformers tend to be more
efficient, to have greater overload capability and to have a longer service life (due to a greater
ability to reduce hot-spot coil temperatures and higher dielectric withstand ratings). Function of
transformer oil:
It serves as liquid insulating media.
• It uses to cool the transformer down.
• It helps to preserve the core and winding as they are fully immersed.
• It prevents direct contact of atmospheric oxygen with cellulose made paper
insulation of windings, which is susceptible to oxidation.

The value of the voltage generated depends on-


• The number of turns in the coil.
• Strength of the field.
• The speed at which the coil or magnetic field rotates

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BAHIR DAR INSTITUTE OF TECHNOLOGY
INTERSHIP IN AMIHARA METAL INDUSTRY AND MACHINE
TECHNOLOGY DEVELOPMET ENTERPRISE
2014 E.C

2.5 Transformer Maintenance and Testing Workshop

There are different machines found in the transformer maintenance and testing work shop
These machines perform different tasks. Some of the machines are shown below;

2.5.1 DC Resistance test


Transformer winding resistance tests are obtained by passing a known DC current through the
winding under test and measured the resistance across each phase. In this condition the DC
resistance of each phase must be equal or the ratio between highest DC resistance to lowest DC
resistance must be less than or equal to 1.02. Apply these conditions for all tap position.

Figure 2.10 DC Winding resistance test

2.5.2 Transformer turn ratio test

Transformer turn ratio test is an essential test. By using transformer turn ratio tester device
connect the positive terminal of device to HV side and the negative terminal of device to the LV
side of the transformer and fill the parameter in to the device. After finished connection and
arrangement press the test button and read results.
In the result we observed that, the theoretical and measured values are much similar and the
error was between -0.4% and +0.4%.

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BAHIR DAR INSTITUTE OF TECHNOLOGY
INTERSHIP IN AMIHARA METAL INDUSTRY AND MACHINE
TECHNOLOGY DEVELOPMET ENTERPRISE
2014 E.C

Figure 2.11 Tern ratio tester

2.5.3 Transformer Winding Machine


Winding machine is mainly used for wind the primary and secondary coil and also used to
unravel the damaged coil of the transformer.

Figure 2.12 Horizontal winding machine

2.5.4 Vacuum Drying machine


This machine is used to dry (under vacuum state) transformer and transformer coil. The
pressure changed vacuum drying process of this machine has fully considered the evaporating
principle and heating process during drying period, which prevent moisture in the deep inside of
insulation can’t be evaporated out due to the temperature increase too quickly during drying
period The temperature of deep inside will be equal to the temperature of surface to that all

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BAHIR DAR INSTITUTE OF TECHNOLOGY
INTERSHIP IN AMIHARA METAL INDUSTRY AND MACHINE
TECHNOLOGY DEVELOPMET ENTERPRISE
2014 E.C

moisture can be evaporated out properly. In this way the drying time can be decreased
significantly, so this machine is most suitable to dry (under vacuum state) transformer prince
and advanced technology.

Figure 2.13 Vacuum drying oven

2.5.5 Insulation Resistance/Megger Test of Transformer

Insulation resistance test is done after drying the active part of maintained transformer and also
after immersed to treated oil.
Insulation resistance test of transformer is essential type test. This test is carried out to ensure
the healthiness of overall insulation system of an electrical power transformer. The insulation
resistance (IR) is a spot insulation test which uses an applied DC voltage. The measured
resistance is intended to indicate the condition of the insulation or dielectric between two
conductive parts, where the higher the resistance, the better the condition of the insulation.
Procedure of Insulation Resistance Test of Transformer:
✓ Firstly, the positive terminal of the megger is connected to primary side and negative
terminal to ground.

✓ Then readings are recorded after application of voltage

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BAHIR DAR INSTITUTE OF TECHNOLOGY
INTERSHIP IN AMIHARA METAL INDUSTRY AND MACHINE
TECHNOLOGY DEVELOPMET ENTERPRISE
2014 E.C

Figure 2.14 . Transformer insulation tester

2.5.6 Oil treatment machine


This machine is used to treat the impurity of transformer oil to increase the breakdown voltage
of oil by filtering solid part and evaporating the liquid part of the impurity.

Figure 2.15 Oil treatment machine

2.5.7 Transformer testing machine


The transformer testing machine is to measure any three phase transformer faults. The
testing machine is testing no load test (open circuit test), on load test (short circuit test),
Induced over voltage test (dv d f test), Magnetic balance test and vector group test.
NO load test (open circuit test): is a transformer is performed to determine no load
loss (core loss). No load tests are tests that apply rated voltage in the primary side at the
no load state of the secondary side.

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BAHIR DAR INSTITUTE OF TECHNOLOGY
INTERSHIP IN AMIHARA METAL INDUSTRY AND MACHINE
TECHNOLOGY DEVELOPMET ENTERPRISE
2014 E.C

ON load test (short circuit test): is the load and excitation are applied to the high
voltage or to the low voltage winding depending up on the rating.
Induced over voltage: test is also called double voltage double frequency test. This test
carried out at a test a frequency which is twice the rated frequency at which the
equipment is supposed to the operate during its life time.
Magnetic balance test: is to verify the imbalance in the magnetic circuit also to identify
its turn faults in the transformer at the early stage of manufacturing work.
Vector group test: is the international electro technical commission (IEC) method of
categorizing the high voltage (HV) winding and low voltage (LV) winding
configurations of three phase transformer. Example wye (Y) HV and delta LV winding
with a 30 degree leads denoted by DYN5, DYN11…

Figure 2.16 . Transformer Test bench

2.6 Major duties of the Intern

As the major duties of Amhara National Regional State Metal Industry and Machine
Technology Development Enterprise is monitoring, operating and maintaining of power
equipment, we daily Monitor Trouble Ticket system with staffs that have privilege. We have
done preventive maintenance on some power devices like power circuit, transformer and heater.

2.7 Challenges faced and measures


2.7.1 Challenges

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BAHIR DAR INSTITUTE OF TECHNOLOGY
INTERSHIP IN AMIHARA METAL INDUSTRY AND MACHINE
TECHNOLOGY DEVELOPMET ENTERPRISE
2014 E.C

There were some challenges we had faced in the internship period. The great problem in the
internship period in AMIMTDE

✓ There are no enough written documents to read about the overall system operation and
device except some equipment manuals.
✓ The company workers are busy and mostly they spent on field work. And sometimes it
is difficult to get the right persons for a particular device. Usually, they didn’t give us
specific and regular task and most of our task were observing when they did their work.
✓ They didn’t provide necessary material for work like data, structural work flow and
most had no any awareness about the university internship program. When faults are
created, we may know the source of the fault or where the problem is created but, to
maintain it is necessary to get appropriate material and permission from the right
persons.

2.7.2 Measures taken to overcome the challenges

To overcome these challenges, we had taken the following measurements which are being
solution.
➢ For the first challenge, we were tried to communicate smoothly and stay more time with
them, through a time we create friendship with them and tell what we want.
➢ For the second challenge, we were tried to communicate with our advisor and operators of
each section, so we were able to solve problems and getting information easily
➢ To overcome the third problem, we tried to record the information's, we trying to see all
parameters consciously
➢ For the last problem we use high sound protective devices like cotton and head phones to
protect us from hearing loss

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BAHIR DAR INSTITUTE OF TECHNOLOGY
INTERSHIP IN AMIHARA METAL INDUSTRY AND MACHINE
TECHNOLOGY DEVELOPMET ENTERPRISE
2014 E.C

CHAPTER THREE 3

3 Benefits Gained from the Internship

3.1 Upgrading theoretical knowledge and Improving Practical skills

In internship program we have get the opportunity to apply our theoretical knowledge in real
world environments. Frankly speaking, our theoretical knowledge got strengthen more by those
practical techniques invested on this internship.

This internship period was a good filed to read about real world problems how to solve it in
engineering departments. Therefore, we gained the following essential things:
➢ Creative and logical approach to solving problems

➢ Clearly understand different motor and transformer and how to configure them

➢ We can understand and practice how to design and implement a transformer

➢ We were able to apply our basic knowledge to design and implement AMIMTDE

3.2 Improving team playing skills


In this company most of the works are done in group. Working together is essential to solve
problems, so it was a good opportunity for us to develop team playing skill. The most important
point in team playing skill is just reach an agreement from different points on the work to be
done. Being positive thinker and having rational reasoning skill is the basic points to understand
each other.
By working together, we improved our practical and theoretical knowledge, problem solving
skill, communication skill, and social interaction. And also, we had observed methods how to
handle challenges and failures that might happen in different aspects. Working together often
leads to increase outcomes of the work.
Team work, especially for engineers is important and involves in every piece of task. Thus, gaining
good team playing skill has been essential for effective completion of the given task. As team
member someone contribute a lot in many ways to improve individual communicative knowledge
of solving the existing problem. Because of these team members, we have been improved the
following attributes:

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BAHIR DAR INSTITUTE OF TECHNOLOGY
INTERSHIP IN AMIHARA METAL INDUSTRY AND MACHINE
TECHNOLOGY DEVELOPMET ENTERPRISE
2014 E.C

➢ Ability of problem identification for solving those problems


➢ Selecting the most appropriate method to solve the existing problem.
➢ Generating or forwarding flexible permissions to solve the problems raised.
➢ A good decision maker.
➢ Accomplishing tasks quickly with as its schedule.
➢ To perform quality work and save time team work is very important in our internship
program and for future.

3.3 Improving interpersonal communication skills

In this internship period we have got a lot of experience and benefit of interpersonal skill. We
became familiar with work environment, time management, work ethics and relation between
the co-workers, practical and theoretical knowledge, and communication skill. It is essential in
order to get information about the work, experience sharing and to create good environment for
work. We developed self-confidence, freely expressing our opinions. Generally, we gained
important communication skill from internship.
During the internship period we recognized that team work is necessary for a given task to be
an accomplished early and qualitatively. Individuals often learn different things from colleagues
through communication. For any individual’s communication is an important way of learning,
which can be defined formally as the act, process, or experience of gaining knowledge or skills.
Communication and the subsequent learning help individual especially engineers more allow
them to gain new professional knowledge and abilities. Good communication is the life hood of
the engineering profession. Even though, it takes many forms, such as speaking, writing and
listening, it has the following usage:
➢ To exchange new ideas and knowledge with the other
➢ Improve to build up self confidence
➢ It improves our speaking and listening skills
➢ To solve the problem in with others.
➢ Improve relationships with the other.
3.4 Leadership skills

Leadership roles not just in a work environment, leadership skills can be applied to any
situation where you are required to take the lead, professionally, socially and even at home.
Generally directing successful leadership results in the employee growth and development with
new skills and capabilities that enables to increase the productivity.

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BAHIR DAR INSTITUTE OF TECHNOLOGY
INTERSHIP IN AMIHARA METAL INDUSTRY AND MACHINE
TECHNOLOGY DEVELOPMET ENTERPRISE
2014 E.C

As we are being a trainer, the tasks assigned to us was not much leadership. We had been
working with supervisor and we made contact with different workers. But we have learnt that
the way how the leaders lead their respective teams, some of important points we have noticed
from the leaders are: the ability to encourage and motivate workers, the ability to communicate
with all workers, the ability to listen problems raised from the team and focus on its solution,
willingness to admit and learn from failures and weaknesses, and the ability to have defined
goals, missions and vision.
A person who is in the position of leadership should be smart enough to manage those
individuals whom he/she is leading. Leadership is a skill to guide, control and monitor people.
This shows that we take a lot of experiences from their leading. They control each employee in
their day-to-day activities. That means we got the chance to saw the strength and weakness of
each leader. We have gained the following benefits which improved our leadership skills:
➢ Committed to the work
➢ Understanding others idea
➢ Peaceful with others
➢ Be honest to the job and other employee
➢ Take care for other.
➢ Help each other.
➢ Get knowledge from the other.
➢ Upgrading with knowledge etc.
3.5 Over All Achievements of the Intern
During our stay in the company, we gain valuable work experience that should enhance our
academic preparation. Thus, we can say we have become familiar with the working
environment and work of conduct which enables us to posses’ appropriate behaviors with
coworkers and the supervisor. We were always on time because we know the importance of
keeping time, being on time is something that is very strongly stressed at AMIMTDE.
Generally, it opens the door to get ready for the next steps to take job for our life career.

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BAHIR DAR INSTITUTE OF TECHNOLOGY
INTERSHIP IN AMIHARA METAL INDUSTRY AND MACHINE
TECHNOLOGY DEVELOPMET ENTERPRISE
2014 E.C

CHAPTER FOUR 4
4 PROJECT AND CONTRIBUTION

4.1 Introduction

4.1.1 Project title: Power factor improvement

4.1.2 Background of study

4.1.2.1 Power factor


Power factor is the ratio between the useful (true) powers (kW) to the total (apparent) power
(KVA) consumed by an item of alternating current (A.C) electrical equipment or a complete
electrical installation. It is a measure of how efficiently electrical power is converted into useful
work output. The ideal power factor is unity, or one. Anything less than one means that extra
power is required to achieve the actual task at hand. Power factor is expressed as a percentage
(%).
Power factor = (real power (KW)/apparent power (KVA)) *100
Real power or true power, P is the power that is used to do work on the load. Active power is
measured in watts (W) and in the electricity bill; it is stately in kilowatt-hours (kWh). It is the
power drawn by the electrical resistance of a system doing useful work.
Reactive power is the power not used to do work on the load.
Generally power factor is called as the cosine of angle between the voltage and current. In an AC
circuit there is generally a phase difference between voltage and current. If the circuit is
inductive, the current is lags behind the voltage and the power factor is called lagging power
factor and if the circuit is capacitive then current leads to voltage and power factor is said to be
leading power factor.
The power factor of an alternating-current device or circuit is the ratio of the active power P to
the apparent power S. Power factor is expressed as a simple number, or as a percentage. It is
given by the equation;
Power factor = P/S

Where; P = active power delivered or absorbed by the circuit or device [W]

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BAHIR DAR INSTITUTE OF TECHNOLOGY
INTERSHIP IN AMIHARA METAL INDUSTRY AND MACHINE
TECHNOLOGY DEVELOPMET ENTERPRISE
2014 E.C

S = apparent power of the circuit or device [VA]

The power factor never exceeds 100 percent or unity because the value of active power can
never be greater than apparent power. Power factor is also a measure of the phase angle between
voltage and current. Where this leads to another equation,

Power factor =cosΘ

AC circuits are made of resistive, inductive and capacitive components. For purely resistive load
like incandescent lighting, the current and voltage are in phase where the current follows the
voltage. For inductive loads case, the current is out of phase with voltage where it lags behind
the voltage except for a few purely resistive loads and synchronous. However, in a capacitive
load the current leads the voltage thus means the current and voltage are out of phase. The most
common capacitive loads are the capacitors used for the correction of power factor of the load.

4.2 Problem statement


In our experience in Amhara Metal Industry and Machine Technology enterprise the main
problem that we observed was the loss of energy due to reactive power. What happens is if the
power factor is less than unity, the line current is greater than the load current, which causes
heating of switch contacts, cables etc. As also it causes to a rise in reactive power, the KVA
demand increases.

This leads to double payment to the company and this leads to penalty charges. So, this project is
very useful to AMIMTDE because it has machines with high inductive loads and as these
inductive loads are the sources of reactive power. The reactive power is the power that
Machinery don’t use which is loss so this project is important not only by saving energy it will
save a fortune for the factory so that they can use the money which is saved from this project for
another important purpose
4.3 Objective
4.3.1 General objective
• The general objective of the project is to design and simulate automatic power factor corrector.

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BAHIR DAR INSTITUTE OF TECHNOLOGY
INTERSHIP IN AMIHARA METAL INDUSTRY AND MACHINE
TECHNOLOGY DEVELOPMET ENTERPRISE
2014 E.C

4.3.2 Specific objective


• To design the logic circuit
• To program and run the micro-controller
• To design current and voltage measuring circuit using current and potential transformers
• To make further data analysis of the billing system of the company
• To design the appropriate rating the capacitor bank
4.4 Material and methodology

4.4.1 Material used

1. Potential transformer: - Voltage to the motor is measured with the help of a potential
transformer. The potential transformer will convert the mains supply voltage to low voltage ac.
That ac voltage is given to zero crossing detectors

2. Current transformer: - the current transformer will convert the load current in to lower values
that current output will be converted into voltage with the help of the shunt resistor. Then the
corresponding AC voltage is given to ZCD.

3. Zero crossing detectors: - The zero crossing detectors are used to convert the input sine wave
signal to corresponding square wave signal. For power factor measurement, the sensing of CT
and are taken from any one of the phases and given to zero cross detector (ZCD) and both
voltage and current are converted square wave, ic741 compare the square wave and the resultant
output is given to the micro-controller.

4. Logic circuit: - In this logic circuit an ex-or gate is used. This ex-or gate is used for
calculation. This intake the output from the two comparators and makes a calculation. Then the
square wave signal is given to the logic circuit in order to find timing between the two pulses.
Then the corresponding pulse output is given to the micro-controller.

5. Microcontroller: -The microcontroller is the flash type reprogrammable microcontroller in


which we have already programmed with our objectives the microcontroller received the

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BAHIR DAR INSTITUTE OF TECHNOLOGY
INTERSHIP IN AMIHARA METAL INDUSTRY AND MACHINE
TECHNOLOGY DEVELOPMET ENTERPRISE
2014 E.C

corresponding square pulse from the logic circuit and performs the mathematical calculation on
the pulse to find the cosine angle.
6. LCD display: - 2x16 LCD display used to display the power factor value.
7. Driver circuit: - This circuit is used to drive the thyristor.
8. Thyristor: - Thyristor is a semiconductor switching device and it is used for adding and cutting
the capacitor.
9. Capacitor: - The capacitor is mainly used to improve the power factor when the normal power
factor is going lagging.

From load Display


Thyristor Inductance

Potential meter
ZCD
Logic Micro
transformer Diver
circuit controller
circuit capacitor
Current Stator
LCD
transformer Resistor

From load keypad

Figure 4.1 Automatic power factor improvement

4.4.2 Methodology

4.4.2.1 Working principle

Voltage to the motor is measured with the help of a potential transformer. The potential
transformer will convert the mains supply voltage to low voltage AC. That AC voltage is given
to zero crossing detectors. Current consumed by the motor is measured with the help of a current

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BAHIR DAR INSTITUTE OF TECHNOLOGY
INTERSHIP IN AMIHARA METAL INDUSTRY AND MACHINE
TECHNOLOGY DEVELOPMET ENTERPRISE
2014 E.C

transformer. The current transformer will convert the load current into lower values that current
output will be converted into voltage with the help of the shunt resistor. Then the corresponding
AC voltage is given to Zero crossing detectors. The zero crossing detectors are used to convert
the input sine wave signal to corresponding square wave signal. Then the square wave signal is
given to the logic circuit in order to find timing between the two pulses. Then the corresponding
pulse output is given to the microcontroller.
Here the microcontroller is already programmed with our objectives.
The microcontroller receives the corresponding square pulse from the logic circuit and performs
the mathematical calculation on the pulse to find the cosine angle.
The cosine value is displayed on the LCD display which is equal to the monitored power factor.
If the monitored power factor is less then unity, then the microcontroller activates the
Thyrister driver circuit. The fixed capacitor is connected across the Thyristor output terminal.
When Thyristor output terminal is shorted through the capacitor the lagging angle is
compensated through lading angle due to the capacitor. If the cosine angle crosses the unity and
moves towards the leading angle suddenly the capacitor is cut off and the angle moves towards
the unity. Thus, the power factor is maintained efficiently.
4.5 Contribution
In the past AMIMTDE had penalized for high reactive power due to the low power factor in
which it cost the company a lot. So, this project should get good attention and be
implemented.by increasing the power factor to approximately 1 the reactive power reduces to the
level where the company is able to save the energy and fortune that could cost AMIMTDE.
Automatic power factor improvement will enhance the company’s productivity and also, it’s a
big relief for the power generating company as the energy they sent will not be lost due to some
means.
4.6 conclusion
Nowadays, in AMIMTDE most of the motors are induction motors. In this motor the no load
power factor will be low due to the magnetizing current which results in high reactive power due
to this the energy will be lost these results in penalty to the company. And so in industries a
large amount of loss occurs. This project will be helpful in maintaining the power factor of an
industry. By adopting this project, mutual benefit is gained over the consumer and Electricity
Board. The project is economically beneficial one.

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BAHIR DAR INSTITUTE OF TECHNOLOGY
INTERSHIP IN AMIHARA METAL INDUSTRY AND MACHINE
TECHNOLOGY DEVELOPMET ENTERPRISE
2014 E.C

CHAPTER FIVE
5 . CONCULSION AND RECOMMENDATIONS
5.1 CONCULSION

The history of AMIMTDE shows how the political, environment, national development policies,
and socioeconomic order have influenced the growth of the metal. Despite the resource and policy
constraints that the AMIMTDE has endured in the past, there has been considerable progress.
AMIMTDE requires enormous resources and strong determination to build and operate an
efficient and modern agricultural infrastructure. The task is further complicated from day to day
as demand increases continuously and new services are expected by the ever-increasing number
of users.

We concluded that the program is very good to know the real-world life and work way
comparing with class study subjects.
We can say that this internship was successful by acquiring sufficient knowledge and practical
skills. Here during this period (as an intern) the hosting company satisfied with the activities of
our performance especially theoretical understanding in every moment.
On the internship period, we have understood so many skills that was the job environment and
what it meant to be a worker, what and why ethics we need to have at the work place and
outside. It was also very effective in developing team playing, interpersonal and leadership
skills.
We observed how to operate, monitor and maintain different types of power devices. We became
familiar with working environment, organization culture, and different electrical equipment.
Generally, we get satisfactory knowledge and more benefited at internship period. This
internship program is real, necessary and important to Electrical engineering students.

5.2 RECOMMENDATIONS
5.2.1 Recommendation for the Company

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BAHIR DAR INSTITUTE OF TECHNOLOGY
INTERSHIP IN AMIHARA METAL INDUSTRY AND MACHINE
TECHNOLOGY DEVELOPMET ENTERPRISE
2014 E.C

There are many preconditions that should be fulfilled to the interns for internship program to be
more effective from all sides of the concerned body, the institute and the hosting company. First
of all, the company and the university should work together to create awareness about the
internship program.

However, we would like to recommend it based on our observation while we were conducting
the internship program. Thus, recommendations are as follow:

➢ The Company should be ready for internship students by preparing project tasks and
motivations to achieve this internship program.
➢ There is no research and development department, this causes the workers to have less
sense to upgrade their knowledge and improve this company
➢ The company worker is considering that internship student is not perform any task and they
are not known in the company
➢ The company must be managing and arrange the time to do different task in rotation, rather
than perform single task during internship period.
➢ In our internship period we have seen many devices that have no function like generators
transformer, different switches and other many devices. So, it will be better, if AMIMTDE
implement workshops to maintain equipment’s like in addition to replacing. As a result, the
company can save lots of money for the purchasing of new materials or devices.
➢ When the main power source is not available mostly the AMIMTDE uses the generator as
alternative source. But the generators have many different side effects like noise,
environmental pollution, fuel consumption, interruption due to many reasons and other. As
result we recommended for the company to use other alternative power source like sun
light because, from sun light we can get many advantages. From sun light we can get clean,
cheap, uninterruptible, sound free and pollution free dc power.
➢ In our internship period we have seen that many types of sensors that installed in
AMIMTDE but most of them didn’t work properly due to many reasons. For example, the
fuel tanks of old generators didn’t have level sensors. As a result, workers lose their time
by manually checking fuel level. But if they install fuel level sensors, they can save time
and solve interruption of generator having no fuel in the tank for the company. So, we
recommended for the company to install and maintain different types of sensors. If the
sensors work properly AMIMTDE can save money, time and reduce network interruption
on this big company.
➢ Finally, I would like to recommend, this company have no power bank so guess how much
energy will be lost in one year.

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BAHIR DAR INSTITUTE OF TECHNOLOGY
INTERSHIP IN AMIHARA METAL INDUSTRY AND MACHINE
TECHNOLOGY DEVELOPMET ENTERPRISE
2014 E.C

5.2.2 Recommendation for Faculty

The Faculty of Electrical and computer make opportunity and communications with any
company to arrange the student to well know company. The schools must arrange before
internship period, to visit some company to reduce any confusion during learning time.
Especially Electrical Engineering student in get problem during ask any support from the
company workers because as we know all in Ethiopia Electrical system somewhat very
sophisticated so the worker of company is afraid in order to support for Electrical Engineering
students so the main difficult to communicate so that faculty must communicate with company
in order to solve such problem.

And finally, it is good to enforce the company to give a specific task, project and responsibility
and management to the intern.

5.2.3 Recommendation for Industrial Linkage

✓ The University Industrial Linkage office should send request or announce to the companies
earlier to the internship period so that the company will have reserve place to the intern to
host him/her.
✓ It is better to automate the interaction between the Industry Linkage and companies. Hence it
is time for the internet communicating with mail will reduce paper transfer b/n them and it is
also essential to save time for the interns.
✓ Finding space for internship program for students is difficult due to many reasons. For
example, most of the company didn’t want to accept the students. So, we recommended for
Industry Linkage to find space from different companies and industries of the country for the
interns. But as we remember it was challenged and difficult to inter in to our interest due to
the retardation of UIL.
✓ In addition to this the University Industrial Linkage should create awareness for private and
governmental organizations how this internship program is very useful to our country and
other concerned people using possible means of communications including advertising in
media.
✓ Generally, the benefit of this internship program for producing efficient engineers is
unquestionable if properly held.

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BAHIR DAR INSTITUTE OF TECHNOLOGY
INTERSHIP IN AMIHARA METAL INDUSTRY AND MACHINE
TECHNOLOGY DEVELOPMET ENTERPRISE
2014 E.C

5.3 REFERENCE

1. Stephen J. Chapman, “Electrical fundamental machinery”, McGraw-Hill, 5th edition. 2012

2. B.L. THERAJA “Text book of Electrical Technology” vol II

3. J. DUNCAN GLOVER, MULUKUTLA S. SARMA and THOMAS J. OVERBYE, “Power


system analysis and design” UNIVERSITY OF ILLINOIS, 5th edition. 2012.
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