Professional Documents
Culture Documents
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.
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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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BAHIR DAR INSTITUTE OF TECHNOLOGY
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
2.7.1 Challenges..................................................................................................................... 23
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BAHIR DAR INSTITUTE OF TECHNOLOGY
INTERSHIP IN AMIHARA METAL INDUSTRY AND MACHINE
TECHNOLOGY DEVELOPMET ENTERPRISE
2014 E.C
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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
1.1 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.
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
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BAHIR DAR INSTITUTE OF TECHNOLOGY
INTERSHIP IN AMIHARA METAL INDUSTRY AND MACHINE
TECHNOLOGY DEVELOPMET ENTERPRISE
2014 E.C
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BAHIR DAR INSTITUTE OF TECHNOLOGY
INTERSHIP IN AMIHARA METAL INDUSTRY AND MACHINE
TECHNOLOGY DEVELOPMET ENTERPRISE
2014 E.C
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INTERSHIP IN AMIHARA METAL INDUSTRY AND MACHINE
TECHNOLOGY DEVELOPMET ENTERPRISE
2014 E.C
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BAHIR DAR INSTITUTE OF TECHNOLOGY
INTERSHIP IN AMIHARA METAL INDUSTRY AND MACHINE
TECHNOLOGY DEVELOPMET ENTERPRISE
2014 E.C
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.
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
➢ 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
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
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BAHIR DAR INSTITUTE OF TECHNOLOGY
INTERSHIP IN AMIHARA METAL INDUSTRY AND MACHINE
TECHNOLOGY DEVELOPMET ENTERPRISE
2014 E.C
• The working rooms (Those are maintenance room, drying room and testing room).
• Safety issue we should have to take while doing Machines (winding, oil treatment,
welding, drying and integrated test machine).
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.
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.
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.
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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.
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
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BAHIR DAR INSTITUTE OF TECHNOLOGY
INTERSHIP IN AMIHARA METAL INDUSTRY AND MACHINE
TECHNOLOGY DEVELOPMET ENTERPRISE
2014 E.C
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BAHIR DAR INSTITUTE OF TECHNOLOGY
INTERSHIP IN AMIHARA METAL INDUSTRY AND MACHINE
TECHNOLOGY DEVELOPMET ENTERPRISE
2014 E.C
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.
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
Coils/winding
Where incoming alternate current (through primary winding) generates magnetic flux, which in
turn develop a magnetic field feeding back a secondary winding.
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BAHIR DAR INSTITUTE OF TECHNOLOGY
INTERSHIP IN AMIHARA METAL INDUSTRY AND MACHINE
TECHNOLOGY DEVELOPMET ENTERPRISE
2014 E.C
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
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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).
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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.
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BAHIR DAR INSTITUTE OF TECHNOLOGY
INTERSHIP IN AMIHARA METAL INDUSTRY AND MACHINE
TECHNOLOGY DEVELOPMET ENTERPRISE
2014 E.C
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;
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
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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.
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.
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BAHIR DAR INSTITUTE OF TECHNOLOGY
INTERSHIP IN AMIHARA METAL INDUSTRY AND MACHINE
TECHNOLOGY DEVELOPMET ENTERPRISE
2014 E.C
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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…
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.
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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.
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
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 were able to apply our basic knowledge to design and implement AMIMTDE
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BAHIR DAR INSTITUTE OF TECHNOLOGY
INTERSHIP IN AMIHARA METAL INDUSTRY AND MACHINE
TECHNOLOGY DEVELOPMET ENTERPRISE
2014 E.C
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
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BAHIR DAR INSTITUTE OF TECHNOLOGY
INTERSHIP IN AMIHARA METAL INDUSTRY AND MACHINE
TECHNOLOGY DEVELOPMET ENTERPRISE
2014 E.C
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,
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.
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
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.
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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.
Potential meter
ZCD
Logic Micro
transformer Diver
circuit controller
circuit capacitor
Current Stator
LCD
transformer Resistor
4.4.2 Methodology
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
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.
✓ 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
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BAHIR DAR INSTITUTE OF TECHNOLOGY