DAR ES SALAAM INSTITUTE OF TECHNOLOGY

DEPARTMENT OF ELECTRICAL ENGINEERING

BACHELOR OF ELECRICAL ENGINEERING
NTA LEVEL 8

SENIOR PROJECT I
Project Title: DESIGN OF OVER AND UNDER VOLTAGE
PROTECTION SYSTEM FOR MILLING MACHINE AT
KAGERA SUGAR CO.LTD
Project Type: PROBLEM SOLVING

Student Name: ANTONY EVODIUS MALAULI

Admission no: 160340321597

Year of Study: 2018/2019

Supervisor Name: Mr. ADAM LIWONDO

January,2019
 DECLARATION

I, ANTHONY EVODIUS MALAURI hereby declare that, my original work

and has not been copied from anywhere or presented elsewhere. Although
information from other sources has been used so as to accomplish this work, a
complete reference of the sources has been given so that it can clearly discerned
what was quoted from other sources.

ii
 ABSTRACT

When grinding mills at camp number seven in Kagera sugar company limited,
there some different problems that normally occur on the motor which is used to
run such milling machine. The motor is operated in a manner that leads different
breakdowns, and theses breakdowns leads to cut services to workers, wasting
time and results to unnecessary maintenance cost of machine. The purpose of this
project is to provide the protection system that will avoid or permanently stop
those motor breakdowns. The method used to accomplish this project is through
collecting relevant data, designing the required circuit, selecting proper
components for the circuit, building the required circuit, testing the required
circuit. The objective of the project is met. The project can be further advanced
to ensure system reliability being more automated.

iii
 ACKNOWLEDGEMENT

Doing project is a monumental task, without the support and understanding of

those close to me, my dream for this project would have never come true. I highly
appreciate the members of staff of electrical department at Dar es Salaam Institute
of Technology for providing me with relevant ideas that led me to the successful
completion of this project. I would like express my heartfelt thanks to Mr.Adam
Liwondo my project supervisor for his advice, techniques, understandable idea
and useful suggestion in doing this project. Also my thanks pass to Mr.Joel Mushi
(Projects coordinator).Also I would like to pass thanks to my family and my
classmates for their highly and conducive corporation.

iv
 TABLE OF CONTENTS

DECLARATION..................................................................................................................... II

ABSTRACT ........................................................................................................................... III

ACKNOWLEDGEMENT .................................................................................................... IV

TABLE OF CONTENTS ....................................................................................................... V

LIST OF SYMBOLS ........................................................................................................... VII

LIST OF TABLES ............................................................................................................. VIII

LIST OF FIGURES .............................................................................................................. IX

INTRODUCTION ................................................................................................................ 1

1.1 Background Information............................................................................................... 1

1.2 Problem Statement ........................................................................................................ 2

1.3 Objectives ..................................................................................................................... 2

1.3.1 Main Objective....................................................................................................... 2

1.3.2 Specific Objectives ................................................................................................ 3

1.4 SIGNIFICANCES OF THE PROJECT .......................................................................... 3

METHODOLOGY .................................................................................................................. 4

2.0 Introduction .................................................................................................................. 4

2.1 Literature Review ......................................................................................................... 4

2.3 Data Collection ............................................................................................................. 4

2.4 Data Analysis ................................................................................................................ 5

2.5 System Design .............................................................................................................. 5

2.6 Circuit Simulation......................................................................................................... 5

2.7 Design Implementation and Testing ............................................................................. 5

2.8 Report Writing .............................................................................................................. 5

3.0 Literature review........................................................................................................... 6

3.1 Existing System ............................................................................................................ 6

v
3.2 PROPOSED SYSTEM ...................................................................................................... 7

3.3 DESCRIPTION ON COMPONENTS OF PROPOSED SYSTEM .............................. 8

DATA COLLECTION ...................................................................................................... 15

4.0 DATA COLLECTION .................................................................................................... 15

vi
LIST OF SYMBOLS

vii
 LIST OF TABLES

No table of figures entries found.

viii
 LIST OF FIGURES

No table of figures entries found.

ix
INTRODUCTION

1.1 Background Information

Kagera Sugar company Limited (KSL) is located in the northern part of Tanzania
about 30km from the boarder of Tanzania and Uganda (Mutukula) and 50km to
east boarder with Burundi. Also it is about 72km away from Bukoba bus stand,
in the north-west direction with latitude 1200m above sea level. Like other
companies Kagera sugar limited depends on different social services like
electricity, water and many others but electricity seemed to be very important in
the process, offering service to different machines like computers and milling
machines in different places of the company. The milling machine save many
workers since it leads to the production of food, but sometimes the motor which
run this machine undergoes different abnormal conditions due to over and under
voltage. Actually sudden fluctuation in voltage is very big and serious problem
in this milling machine and it causes losses in electrical circuit of the motor. These
losses cause low power factor in the supply and by much amount of power is
going to be wasted. These fluctuations may significantly impact the power quality
as well as the reliability of other voltage controlling even other devices.
Therefore; due to this fluctuation, various costly and precious motor for this
milling machine may get damaged. Basing on overview, the demand of electrical
energy increases more generating units, transmission lines are added to the
system, which in turn increases its complexity, making the system more prone to
fault disturbances.

Now -a-days, greater demands have been placed on the transmission network,
and these demands will continue to rise because of increasing number of
nonutility generators and great competition among utilities themselves. Increased
demand on transmission, absence of long term planning, and the need to provide
open access to generating companies and customers have resulted in less security
1
and reduced quality of supply. Several types of power enhancement devices have
been developed over the years to protect equipment from power disturbances, but
these devices can also fail or malfunction sometimes. Thus the need for more
security is always wanted and that’s why I decided to come with this idea, that
will generally provide the security of milling machine that control motor from
being damaged again.

1.2 Problem Statement

Kagera sugar company limited provides different services to its workers
including machine for grinding mills. This machine has been undergoing some
problems like motor breakdowns, which cause workers to look for alternative
milling services far away from their residence. Also temporary hunger has been
a big catastrophe to camp number seven at kagera sugar company limited.

Due to the fact that, the voltage fluctuations from substation around this area and
voltage surges due to the lightning and switching impulses tends to cause these
voltage abnormalities (over voltage and under voltage). Therefore this comes the
big problem since it cuts services to workers, wasting time and results to
unnecessary maintenance cost of machine.

1.3 Objectives
The objectives of this project is divided into two categories

i. Main objective
ii. Specific objectives

1.3.1 Main Objective

This is the statement of the trend of learning activity that can describe the general
orientation of a learning curriculum.

2
Now the general or main objective of my project is to provide protection system
for milling machine that will avoid motor breakdowns.

1.3.2 Specific Objectives

This is defined as the trend of learning activity, but it is formulated in terms of
observable behaviors. Now the following are the specific objectives of this
project;

i. To design an electrical circuit and protection system that will avoid

motor breakdowns in the milling machine
ii. To build a circuit.
iii. To test a built circuit.

1.4 Significances of the project

The following are the significances of this project:
i. Protects the motor of milling machine against abnormal voltages.
(Over and under voltage), that normally cause breakdowns
ii. Increases lifespan of the motor for milling machine
iii. Reduces running cost of the machine.
iv. Keep the efficiency of the machine.
v. Leads to the reduction of temporary hunger to the workers

3
 METHODOLOGY

2.0 Introduction
This chapter gives explanations of various procedures which were taken in order
to fulfill the expected objectives of the project. The following are explanations of
some approaches, on performing my project the following are methodologies that
I will use to accomplish my project

i. Literature review
ii. Data collection
iii. Data analysis
iv. System design
v. Circuit simulation
vi. Design implementation and testing.
vii. Report writing

2.1 Literature Review

This case discusses about the existing system and the proposed system whereby
it discusses the previous relevant works, also comprises the expiations and
definitions of the devices, different techniques involved in the project completion
and the explanations of other people(authors) whom are aware to the device
concern.

2.3 Data Collection

The data collected will be obtained through questionnaire, survey, observation
and review. The data obtained will contain data to verify problem existence and
requirements for the proposed system design.

4
2.4 Data Analysis
This process will involve evaluation of data collected, with the aim of obtaining
useful information which will help in drawing conclusion on what to be used in
system design. Data analysis will aid in deciding the type of software and
hardware to be used.

2.5 System Design

System design will involve planning of how the system will be constructed in
accordance to data analysis conclusion. This will include defining the
architecture, components, modules, interfaces and data for the proposed system
which aims at achieving the objectives set.

2.6 Circuit Simulation

This will involve the use of mathematical models to replicate the behavior of the
actual circuit. Circuit simulation will provide practical feedback in designing of
real world system hence allows determination of the correctness and efficiency
of the design before actual system construction.

2.7 Design Implementation and Testing

This will involve realization of the design using specified hardware after
successful circuit simulation. The prototype will then be tested to check its
functionality with reference to specified performance parameters.

2.8 Report Writing

This will involve recording the summary of the work done in every method used
in achieving the objectives set.

5
3.0 Literature review
Through doing the literature review, the following aspects should be considered

1. Studying the existing system

2. Proposing the new system

3.Reviewing the different works/projects/ books which are relevant to my project

This case discusses about the existing system and the proposed system whereby
it discusses the previous relevant works, also comprises the expiations and
definitions of the devices, different techniques involved in the project completion
and the explanations of other people(authors) whom are aware to the device
concern.

3.1 Existing System

The available system of the motor in milling machine has no means of protection
against over and under voltage occurrence from the supply voltage because;

I. Low voltage(Under voltage) lead to heating of motor

windings due large amount of current drawn from the
supply.
II. Over voltage tends to push the magnetic portion of motor
into saturation. This cause the motor to draw excessive
current in the effort to magnetization, then motor will
tolerate a certain change in voltage that generally damage
the motor

6
 This is shown to the block diagram of the existing system in (figure. 1)

AC MOROR FOR
SWITCHING
VOLTAGE MILLING
MECHANISM
SUPPLY MACHINE

Figure 1: Shows the block diagram of existing system

3.2 Proposed system

The proposed system will consist a tripping mechanism operation which is
intended on protecting the three phase induction motor of milling machine against
abnormal voltages. (Over and under voltage) that normally cause breakdowns in
controlling motor. The process of this system is whenever there an overvoltage
or under voltage the relay sense the input from operational amplifier and gets trip
and the load is off. Thus it protects the electrical motor against breakdowns. This
system also will lead to Increase lifespan of the motor for milling machine, reduce
running cost of the machine and generally will Keep the efficiency of the
machine.

7
 POWER LOAD SWITCHING
SUPPLY (MOTOR) MECHANISM

POWER REGULATING
CONVERSION
DEVICE

PRESETING COMPARATING
UNIT UNIT

Figure 2: shows the block diagram of proposed system

AC supply is stepped down to 12 V by using a step down transformer. The AC

supply is converted to DC supply through bridge rectifier. The supply is then
filtered by capacitors connected across rectifier to reduce harmonics. Then the
unregulated supply is then fed to voltage regulator whose output is given to the
comparators and relay as supply. The unregulated supply from bridge rectifier is
fed to preset 1 and preset 2 as input. The preset 1 and preset 2 are potentiometer
1 and potentiometer 2 respectively connected to comparators as command or
input. The Preset conditions can be adjusted. Further, the comparators are
connected to the relay and load is connected to relay. Whenever there is
overvoltage or under voltage the comparators analyze the preset conditions and
gives the signal to the relay, the relay trips and the load get switched off. Thus
protects the electrical motor for milling machine against breakdowns caused by
the abnormalities.

3.3 DESCRIPTION ON COMPONENTS OF PROPOSED SYSTEM

a. Step down Transformer

8
The transformer actually steps down and converts 230-volt power to 30 volts or
less. Sometimes transformers have more than one voltage connection point,
called a multi-tap transformer. Transformers are constructed of two tightly wound
coils encased in a metal cover. Since the two coils are placed closely together in
the case, current flows through the primary winding (the 120-volt side) and as it
does this, it produces a magnetic flow. This flow produces current in the second
coil winding (secondary winding) that produces the low voltage output. The
primary coil has more windings than the secondary coil. Because of the reduced
number of windings in the secondary coil, the voltage output is much less.
Secondary windings usually produce voltages between 8 and 24 volts. An
electronic low voltage transformer also contains an electronic device, called an
inverter, which allows the size of the low voltage transformer to be substantially
smaller. An inverter and a small transformer make up the main components of
what we normally call an electronic low voltage transformer (Mohammad Shah
Alamgir and Sumit Dev, “Design and Implementation of an Automatic Voltage
Regulator with a Great Precision and Proper Hysteresis”, Vol.75, year 2015)

Figure 3: Low Voltage Step down Transformer

b. Bridge Rectifier:
A diode bridge is a device that changes Alternating Current (AC) to Direct
Current(DC). A diode bridge is an arrangement of four (or more) diodes in a
bridge configuration that provides the same polarity of output for either
polarity of input. When used in its most common application, for conversion
of an alternating current (AC) input into direct current a (DC) output, it is
9
 known as a bridge rectifier. A bridge rectifier provides full-wave rectification
from a two wire AC input, resulting in lower cost and weight as compared to
a rectifier with a 3-wire input from a transformer with a center-tapped
secondary winding. The essential feature of a diode bridge is that the polarity
of the output is the same regardless of the polarity at the input.

Figure 4: Bridge Rectifier

c. Voltage Regulator
A voltage regulator is an electrical regulator designed to automatically
maintain a constant voltage level. A voltage regulator is an example of a
negative feedback control loop. It may use an electromechanical mechanism,
or electronic components. Depending on the design, it may be used to regulate
one or more AC or DC voltages. Electronic voltage regulators operate by
comparing the actual output voltage to some internal fixed reference voltage.
Any difference is amplified and used to control the regulation element in such
a way as to reduce the voltage error. This forms a negative feedback control
loop; increasing the open-loop gain tends to increase regulation accuracy but
reduce stability (avoidance of oscillation, or ringing during step changes).
There will also be a trade-off between stability and the speed of the response
to changes.

10
 If the output voltage is too low (perhaps due to input voltage reducing or load
current increasing), the regulation element is commanded, up to a point, to
produce a higher output voltage - by dropping less of the input voltage (for
linear series regulators and buck switching regulators), or to draw input
current for longer periods (boost-type switching regulators); if the output
voltage is too high, the regulation element will normally be commanded to
produce a lower voltage.
However, many regulators have over-current protection, so that they will
entirely stop sourcing current (or limit the current in some way) if the output
current is too high, and some regulators may also shut down if the input
voltage is outside a given range.

Figure 5: Diagram of voltage regulator

d. zener diode
A Zener diode is a type of diode that permits current not only in the forward
direction like a normal diode, but also in the reverse direction if the voltage is
larger than the breakdown voltage known as "Zener knee voltage" or "Zener
voltage".A conventional solid-state diode will not allow significant current if
it is reverse-biased below its reverse breakdown voltage. When the reverse
bias breakdown voltage is exceeded, a conventional diode is subject to high

11
 current due to avalanche breakdown. Unless this current is limited by circuitry,
the diode will be permanently damaged. In case of large forward bias (current
in the direction of the arrow), the diode exhibits a voltage drop due to its
junction built
in voltage and internal resistance. The amount of the voltage drop depends on
the semiconductor material and the doping concentrations. (Silicon institute
of technology, “Power quality problem identification and protection scheme
for low voltage system”, Orissa, November 2010.)

Figure 6: show the real structure and symbol of zener diode

e. comparator
Is the device that compares two voltages or currents and outputs a digital
signal indicating which is large. It has two analogy input terminals and one
binary output and output is usually ideal.
The comparator consists of four independent, high gains; internally frequency
compensated operational amplifiers which were designed specifically to
operate from a single power supply over a wide range of voltages. Operation
from split power supplies is also possible and the low power supply current
drain is independent of the magnitude of the power supply voltage.

12
f. Relay
A relay is an electrically operated switch. Many relays use an electromagnet
to
operate a switching mechanism mechanically, but other operating principles
are also used. Relays are used where it is necessary to control a circuit by a
low-power signal (with complete electrical isolation between control and
controlled circuits), or where several circuits must be controlled by one signal
A simple electromagnetic relay consists of a coil of wire surrounding a soft
iron core, an iron yoke which provides a low reluctance path for magnetic flux,
a movable iron armature, and one or more sets of contacts (there are two in
the relay pictured). The armature is hinged to the yoke and mechanically
linked to one or more sets of moving contacts. It is held in place by a spring
so that when the relay is de-energized there is an air gap in the magnetic
circuit. In this condition, one of the two sets of contacts in the relay pictured
is closed, and the other set is open. Other relays may have more or fewer sets
of contacts depending on their function.

The relay in the picture also has a wire connecting the armature to the yoke
When the coil is energized with direct current, a diode is often placed across
the coil

13
to dissipate the energy from the collapsing magnetic field at deactivation,
which would otherwise generate a voltage spike dangerous to semiconductor
circuit components. Some automotive relays include a diode inside the relay
case. Alternatively, a contact protection network consisting of a capacitor and
resistor in series may absorb the surge. If the coil is designed to be energized
with alternating current (AC), a small copper "shading ring" can be crimped
to the end of the solenoid, creating a small out-of-phase current which
increases the minimum pull on the armature during the AC cycle.
(http://www.allaboutcircuits.com/vol_2/chpt_9/6.html)

Figure 7: shows the real picture of relay and its parts

14
 DATA COLLECTION
4.0 DATA COLLECTION
The data were collected from source of problem by considering the number of
workers living in the area of camp number seven at Kagera sugar company
limited.
The workers’ residence of that area are arranged systematically as there are 18
barracks and every barrack has at least 48 rooms, then the maximum workers
living that place are about 864.All these people depends on the milling machine
for grinding their mill for food purpose. On collecting data, I basically dialed with
specifications and how motor for milling purpose can be rated on protecting its
breakdowns so as to save the large number of people against the temporary
hunger and other catastrophe.
ITEMS SPECIFICATIONS UNITS
AC VOLTAGE SUPPLY THREE PHASE
(400-415)/50Hz
MOTOR FOR VOLTAGE 415V
MILLING MACHINE POWER RATED 22.5KW/22.9HP
CURRENT 38A
AMBIENT
TEMPERATURE 40˚C
OVERVOLTAGEAND
UNDERVOLTAGE ON THREE PHASE 400<V<415
MILLING MACHINE

15
OVERVOLTAGE AND
UNDERVOLTAGE THREE PHASE 400V +_6%
TOLERANCE OF
MAINS (TANESCO)

16