DEBRE MARKOS UNIVERSITY

COLLAGE OF TECHNOLOGY
DEPARTMENT OF ELECTRICAL AND COMPUTER
ENGINEERING
INTERNSHIP REPORT & PROJECT

Outline for report

Introduction
Background of the company
The main assembly accessories
Objectives of the company
Main products of the company
Main customers of the company
Production process
Overall internship experiences
Over all benefit I gained from the
internship
Conclusion and Recommendation

Introduction
Currently Ethiopia has given a special attention
to electric power generation, transmission and
distribution to make more reliable and support
the economy.
To overcome electricity problems and to
support the economy of the country EPEI
established compact distribution substation
and power factor corrector factory.
The major aim of installing PFC is to minimize
reactive power flow in supplying system
The interest for compensating reactive power
has been growing

Contd
Reactive power compensation can be
handled using different types of methods.
Advantages of compensating reactive
power
Less total KVA in the plant
Reduction of power loss
Savings on the electricity bill
Reducing the installation size
Increasing available power

Background of the company

There are nine industries incorporated under
Metals and Engineering Corporation.
Ethiopia Power Engineering Industry is one
branch and under this Power Factor Corrector
and Compact distribution Substation Factory.
Power Factor Corrector and Compact distribution
Substation factory was established on 2
November 2003 EC
Power Factor Corrector and Compact distribution
Substation factory is found in Addis Ababa city
around Akaki Kality subcity

The main assembly

accessories
Enclosure :The house of PFC & CDSS
It has galvanized steel base frame
It is totally enclosed aesthetically
acceptable metal cladding.
Switchgears: devices which control the
circuit under faulty and normal conditions
Transformer: IS a three phase twowinding distribution transformers
complete with necessary fittings for
15/0.4KV and 33/0.4KV

Contd
Capacitors: Forms the core component in
power factor corrector equipment .
Storing reactive power and
release it whenever the load want
Bus bar: It is the electrical conducting path
all the components in the APFC system
are connected
Circuit breaker: : Is a device used in safety
shut-off the flow of electricity in a circuit if
there is too much current to operate safely

Contd
Discharge resistor: Capacitors discharged
in order to protect against electric shock
Intelligent Module: Brain of APFC
Electrical communication between the
capacitor bank and the system load is
held using this equipment
Switching Module: Are act as switches.
Has LEDs which are used to identify
the condition of capacitors

Contd
Cables: Are electric conducting path
which connect various components
Cooling fan: Is a rotating device for
cooling purpose .
Thermostat: Is a device for sensing
the surrounding tempreture

Objectives of the company

To save the electric power of the

country
To smooth the countrys power
distribution
To open job opportunity
To utilize internal resources and
reducing the capital investment
To develop skilled man power
To facilitate industry by smooth power
supply

Main products of the

company
The main product of the company
are power factor corrector and
compact distribution substation
PFC products
50KVARs,75KVARs,100KVARs,150KVA
Rs,200KVARs,250KVARs,300KVARs,4
00KVARs,500KVARs
Two type of PFC based on operation:
These are APFC and FPFC

Contd
Fixed power factor corrector:
operates in manual setting without
any controller
It has these major parts: enclosure,
circuit breaker, bus bar, capacitor,
discharge resistor, fan, thermostat,
cables
The wiring diagram of fixed power
factor corrector look likes

Contd

Contd
Automatic power factor corrector: It
operates automatically with controller.
The design of APFC contains:
Intelligent module, switching module,
contactor, current transformer, voltage
transformer, enclosure, circuit breaker,
bus bar, capacitor, discharge resistor,
cables
The wiring diagram of APFC look likes

Contd

Contd
Models of compact distribution substation
are
METEC 315/15, METEC 500/15, METEC
630/15, METEC 800/15, METEC 1250/15,
METEC 315/33, METEC 500/33, METEC
630/33, METEC 800/33, METEC 1250/33.
CDSS have these components
transformer, HV switch gear, LV switch
gear, bus bar, cables, cooling fan,
thermostat, wires and lighting lamps

Main customers of the

company
The factory distributes its products
mainly for:
EEU
ministry of agriculture,
sugar factory
And other private company

Production process
Manufacturing power factor corrector
needs enclosure, cables, circuit breaker,
bus bar, capacitor with discharge resistor,
thermostat, fan, contactor, control units
There are six teams in PFC workshop:
Testing team, bus bar assembly, cable
preparation team, capacitor bank
assembly, control unit assembly and
breaker assembly team

Overall internship experiences

Almost all tasks in the company are manualy

operated so I was part of that activity.
I have worked in all section of company such
as bus bar assembling, capacitor bank,
breaker assembling, control unit, cable
preparation, testing
Before I start to perform tasks in the company
reading rules and regulations, following
presentations, introducing with workers, and
general visual observation

Contd
Testing control unit equipment and
passive electrical parameters
In this functionality of switching
module, intellegent module, network
cable are checked
The value of discharge resistor and
capacitor are checked
bus bar assembling: receive row
material

Contd

Contd
Fit bus bar insulator to the selected bus bar
Fit u-bar & bus bar supporter (Ruler) in to the
prepared enclosure

Finally fit the selected insulator bus bar in to

the bus bar supporter (ruler)
Capacitor bank assembling: Receive row
materials
Switch tray, Contactor, Capacitor bank, Ground
cable, Bolt and nut
Fix discharge resister to capacitor using pizo
drive properly

Contd

Contd
Drilling switch tray hole for switch module
Fit the number of capacitors to the capacitor
bank based on the required kVAR rating
Remove the insulation part of ground cable
and tight it to the capacitor ground terminal
Connect wires between contactors to
connector and bus bar
Finally, the assembled capacitor bank insert
to u-bar

Contd

Breaker Assembling

Contd
For 50,75,100KVARs 250A ckt breaker
For 150,200,250,300 KVARs 630A ckt
breaker
For 400 and 500 KVARs 800A Ckt breaker
Mark and drilling breaker stand hole
Fit circuit breaker on breaker stand
Insert the assembled in to the panel
Connect bus bar with circuit breaker
Connect ground cable to panel

Cable preparation
Receive cables and cable lugs
Prepare and cut cables of different
sizes in different lengths
cable cutting length for (50-200)
KVAR
Cap to contac 22cm,contac to
conn 38cm, conn to bus bar 85cm ,
bus bar to CB 40cm
crass sectional area 10 and 16-70
square mm

Contd
Bending and removing insulation in
both sides of the specified cable to
connect breaker to bus bar
Cutting and removing of insulation
Finally, lugging to those prepared
cables

Control unit assembly

Receive intelligent module,
switching module, fan, thermostat,
Data cable , flexible Condit
Connect temperature sensor to
thermostat
Fan assembly both its rotor and
cover parts
Proper connection of wires to fans,
thermostat and bus bar

Thermostat with fan connection

Final power factor corrector testing

Receive final product APFC, FPFC
Insulation test - Phase to body, Phase
to phase and Phase to neutral in
infinite (Giga & Tera ohm
Capacitance -Delta,3*154mF
Temperature - >250c.
Bus bar distance, cable is tightened
well
circuit breaker

Benefit gained from internship

Practical skill: Interpreting theories,
electrical testing, assembling
Theoretical skill: internship program has
a great benefit for upgrading theoretical
knowledge . For mention, , instrumental
transformer, capacitors, cables, bus
bars, circuit breaker, arresters
Interpersonal skill: team work,
respecting, trusting, punctuality

Conclusion
Generally speaking, one can conclude that
through the application of PFC
There is better utilization of electrical
machine
Better utilization of electrical line
Reduction of loss and reduction of voltage
drop.
smooth relation between customer and
government

Recommendation
There is idleness in the company by
the shortage of row materials, so the
company should hard work with
suppliers
Currently most industries have non
linear loads i.e. absorb non sinusoidal
current which causes on the supply
side of the network harmonic effect,
so I recommended that harmonic
filter should be inserted in PFC

Contd
There is a problem of selecting
cables, circuit breakers, bus bars and
capacitor size. So I recommended
that there must be proper selection
of these row materials for a specific
PFC.
The size of the capacitor is large, as
much as possible it must be reduced

Outline for case study

Title of the case study

Background
Statement of problem
Objectives of case study
Review literature
Design and selection
Conclusion
Recommendation

Title of the case study

Design and selection of
harmonic filter, cable, circuit
breaker, bus bar and capacitor
for 500 KVARs PFC

Background
Non-linear loads are loads in which the current
waveform does not have a linear relationship with
the voltage waveform
Non-linear loads generate voltage and current
harmonics
Harmonics are the phenomenon which most
heavily affects power factor correction capacitors
The main apparatus generating harmonics are:
personal computers
fluorescent and gas discharge lamps
variable speed drives

Statement of problem

PFC and CDSS factory have good work flow but

there is a problem of selecting cables, circuit
breakers, bus bar and capacitor size in the shop
currently most industries have non linear loads
i.e. absorb non sinusoidal current which causes
on the supply side of the network harmonic
effect, so harmonic filter should be inserted in
PFC
So this paper is subjected to address this
problems

Objectives of case study

To design and select cable, circuit

breaker, bus bar, capacitor and
harmonic filter for a specific power
factor corrector(500KVARs)
To eliminate wastage of materials
To minimize harmonic effect in PFC
installed circuits

Review of literature and

theory
There are two shops. these are PFC
and CDSS
This paper is done for PFC shop,
since the product of PFC has no
harmonic filter as well as there is no
proper use of electrical
devices(cable, CB, bus bar,
capacitor)
Capacitor:It is a passive dipole
consisting of two conducting surfaces

Harmonic filter
Are connected in series with capacitors
The harmonics created by the VSD are
5th, 7th, 11th, 13th, etc
Harmonic effects: overload and resonance
Overload: The presence of harmonics in
the electrical network cause of
malfunctioning of the equipment such as
overloading of the neutral conductor
Increase of losses in the transformers

Contd
Resonance: Is phenomenon which occurs
when the inductive and the capacitive
reactance are equal i.e. Xc = Xl
Resonance occurs at a precise frequency,
which is called resonance frequency, fr
Fr =

 Bus bar: Bus bar is the electrical conducting

path, to which all the components in the
PFC system are connected
Cables:Is electrical conducting path which
loop the power circuit in the system.
Circuit breaker: Is a device used in safety
shut off (i.e. that can automatically stop)
the flow of electricity in a circuit if there is
too much current to operate safely

Design and selection

Design current(Ib) : the rating of the
electrical apparatus to be operated
Nominal rating of the protection(In):rating
of the protective device
This value is taken from the table and it
has standards which starts from 6, 10, 16,
80,100,110,125.
Current carrying capacity(Iz):the maximum
current that can be carried continuously by
the conductor under a normal operation

Contd
Ambient temperature :Factor that is considered
due to the temperature the surrounding
Protection by BS 3036 fuse :It is a rating factor
which is considered when we are use fuse for
over current protection and the value is 0.725
Grouping :is the rating factor to be used where
cables are grouped or touched with each other.
Most of the time its considered for cables
which have different size.

Determining the cable size between

breaker and bus bar

Contd
Then selection of rating of protective device
In = 800
C. Relevant correction factors
Ambient temperature
k1=1.03 from table
Use fuses Bs3036 for over current protection
Take K2=0.725
Then Rcf=0.725 1.03
=0.74675

Contd
Determination of cable current
carrying capacity (Iz)
Iz = In/Rfc
= 800/ 0.74675
= 1071.3A
Choose the cable size to suit Iz from
table
A=400 square mm

Cable between bus bar and

capacitor

Bus bar Selection

Calculating size of bus bar from the following
details
Design parameter
Supply the system three phase,380v AC,50Hz
Fault level 3067.24A
Duration of fault one second
Rated power 500Kvar
Ambient temperature 25 c
Maximum permissible operating temperature
85 C at fault

Case one
Determination of minimum size of
conductor for any fault by considering
heating effect during fault

Contd
from the above A = 33 square mm
Case 2
By considering derating factor
during operation
desired current rating of the
bus bar

Contd

Contd

Accepter circuit
Capacitor and reactor connected in
series is referred to as an acceptor
circuit

Contd
Detuning factor: defined as ratio of
reactor`s reactance with respect to
reactance of capacitor
Indicates the capability of the
acceptor circuit to filtrate the higher
order harmonics
First calculation the value of
capacitor from rated values
Use delta connection

Contd

Contd

Conclusion

Harmonics flow to low impedance devices

The low impedance devices attract
harmonic current from all sources
connected to the system
Then they dissipate the harmonic current as
heat
Heat dissipation should not be considered a
loss caused by the harmonic filters as this
waste heat already existed in the system in
unusable frequencies

Contd
This heat is dissipated by the
harmonic filter instead of being
exported to the utility grid
By using proper electrical devices
one can reduce wastage of row
materials as well as minimize voltage
drop

Recommendation
proximity and skiny effect should be
considered in bus bar design
The work should be simulated by
MATLAB