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ALMAKTOUM COLLEGE OF ENGINEERING AND TECHNOLOGY [AMCET]

STUDENT ’S NAME; THOMAS COSTANTINE TARIMO

REGISTRATON NUMBER; NS 2774/0138/2011

CLASS; BASIC TECHNICIAN IN ELECTRICAL AND ELECTRONICS

ENGINEERING

DEPARTMENT; ELECTRICAL ENGINEERING

LEVEL; NTA LEVEL 4

MODULE; INDUSTRIAL PRACTICAL TRAINING [IPT]

TITLE; AUTOMATIC –STAR DELTA MOTOR STARTER

INDUSTRIAL TRAINING REPORT AS CONDUCTED AT TAZARA WORK SHOP

P.O.BOX 4011O DAR ES SALAAM

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Table of Contents
HISTORICAL BACK GROUND 4
TASK UNDERTAKEN 12
Automatic star-delta motor starter 15

WORKING PRINCIPLE OF STAR DELTA 16

PROCEDURE AND INSTALLATION 17
CONCLUSION AND RECOMMENDATION 19

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Acknowledgment

Firstly, thanks to GOD who make me alive until now am writing this report.
Secondly, to my parents and relatives for raising me until now. Third, to the people
who surrounded me especially my fellow students who supported me on every task
that assigned by our supervisors. Fourth, special thanks to management of TAZARA
WORKSHOP for allowed me to conduct my practical training on their institute. And
lastly, special thanks to my supervisor MR SALEHE.R..LYMO for his cooperation
and make me understand different things about electrical and electronics especially
about motor, transformer, automation, electrical power transmission & distribution
and industrial wiring and maintenance.

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CHAPTER ONE

INTRODUCTION

HISTORICAL BACKGROUND OF TAZARA.

The idea to connect Central and Southern African States with the eastern coast
through a rail link started as far back as 1947. Both Tanganyika (now Tanzania) and
Northern Rhodesia (now Zambia) had for a long time wished to agriculturally develop
their vast areas in the South West (of Tanganyika) and North East (of Northern
Rhodesia), respectively. On the Tanganyika side, plans for this had been discussed
for many years while on the Northern Rhodesian side the suggestion was beginning
to receive prominence and support by 1963 through the advocacy of Dr Kenneth
Kaunda. Earlier, the colonial settlers had undertaken a number of surveys into the
project and nearly all had declared that the proposed line was economically
unjustifiable. This was at the time of liberation agitations and it was apparent that
these conclusions were laced with political thinking. The settlers feared that such a
rail link would affect their interests in the region.

HOW IAN SMITH TRIGGERED ACTION.

On 11th November 1965, the administration of Ian Smith in Rhodesia (Zimbabwe)
whose Rhodesian Front party opposed an immediate transfer of power to black
majority rule in the self-governing British colony, unilaterally declared independence
from the United Kingdom. The Unilateral Declaration of Independence (UDI), as it
were, triggered various effects on the scene. First, UDI had the effect of intensifying
the liberation struggle in which Zambia played an active role as a frontline state.
Being landlocked, the Smith regime tried to intimidate Zambia out of her support for
the liberation struggle by cutting her only outlet to the sea – the road and rail trunks
from Zambia to the sea ports in South Africa, passing through Rhodesia. The leaders
of Tanzania (pace at which the TAZARA project was implemented.the late Mwalimu
Julius Nyerere) and Zambia (Dr. Kenneth Kaunda) who were aware of Zambia’s
dependence on the southern route and its implications visualized that the North East
Rail Link was the only other way for Zambia to maintain economic and political

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independence. In a significant way, therefore, Ian Smith’s UDIspurred the

proponents and even quickened the

HOW CHINA RESCUED THE SITUATION.

Tanzania and Zambia clearly had the motive to construct TAZARA. But it was also
very clear from the beginning that this mammoth project would require huge amounts
of funds to take off. The Western countries were first approached for assistance to
build the line but as expected they rebuffed the idea, insisting that “the project was
economically not viable.” This view, which was equally supported by the World Bank,
meant that assistance from that quarter was not possible. The Government of the
People’s Republic of China, under the wise leadership of the late Chairman Mao
Tse-Tung were approached and readily accepted to support the project. The
Chinese leadership saw the wider necessity of the line and thus offered to finance it
as a turnkey project. The Chinese offered to provide the finances for construction,
expertise and equipment, including buildings, workshops, training school and related
infrastructure.

. AGREEMENT IS SIGNED.
On 5th September 1967, an Agreement for the construction of TAZARA was
concluded in Beijing, China, between the three Governments of China, Tanzania and
Zambia. The initial idea was for the railway line to start from Kidatu in Tanzania to
Kampoyo in Zambia.

TAZARA IS ESTABLISHED.
The Tanzania-Zambia Railway Authority was established in March 1968 and the
survey and design work commenced in October 1968 and finished in May 1970. The
surveys by the Chinese produced favorable recommendations, which completely
disregarded all conclusions of earlier surveys. By now it had been decided that the
line would start from Dar es Salaam and end at KapiriMposhi.

CHINA OFFERS AN INTEREST-FREE LOAN.

In July 1970, China agreed to give Tanzania and Zambia an interest free loan
repayable in thirty years totaling Yuan 988 million to cover costs of constructing the
line and supporting infrastructure of Stations and the Training School as well as the
supply of motive power and rolling stock.

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. CONSTRUCTION BEGINS.
Construction of the line started in October 1970. The then Presidents Dr. Kenneth
Kaunda of Zambia and late Mwalimu Julius Nyerere of Tanzania officially
inaugurated the commencement at Dar es Salaam in Tanzania and Kapiri Mposhi in
Zambia, respectively. This was the beginning of the most awe-inspiring engineering
feats ever performed by China in Africa.

PRODUCTS AND ACTIVITIES UNDERTAKEN BY THE FIRM.

Engineering workshops.

We have three engineering workshops, located in Dar es Salaam, Mbeya, in

Tanzania and Mpika in Zambia. The Mbeya workshop was specifically set up to
undertake the maintenance of general electric/krupp (Diesel Electric) locomotives
and all scopes of repair, including the rehabilitation of locomotives from serious train
accidents, DE locomotives are TAZARA’s mainstay, employed mostly in mainline
operations.

The Dar es Salaam and Mpika workshops, on the other hand, are exact replicas and
were particularly established to conduct wagon and coach maintenance and repairs
and to offer general engineering services and works that the railway may require
including

 Steel casting
 General purpose and light metal casting

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 Forging services
 Coiling of springs
 All basic machining processes, including planning, grinding, turning, shaping, and
more
 Heat treatment and electroplating
 Laboratory services
 Equipment maintenance, repair and overhaul
 Manufacturing of component parts for factories.

DURATION OF INDUSTRIAL PRACTICAL TRAINING

Start from 2 august,2021 to24 September 2021

I am worked on department of equipment maintenance (electrical)

. Passenger services.

We run three types of passenger trains, i.e. Express, Ordinary and Special Trains.
Apart from conveying people, passenger trains also transport parcels and luggage
using the parcel vans attached to the passenger trains. Each parcel van can carry up
to 15.7 metric tons of parcels and depending on the demand, one or more vans can
be attached to the train at a time.

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. Freight services.

We operate two types of freight trains i.e. through traffic and local traffic trains.
Through traffic trains convey cargo originating from Dar es Salaam in Tanzania to
New KapiriMposhi in Zambia and vice versa. Local traffic trains convey intermediate
cargo

Quarries.

We maintain and operate two quarries: the Mununga Quarry in Mpika, Zambia and
the Kongolo Quarry in Mbeya, Tanzania. Each of the two quarries has the capacity
to produce more than 2,000mt of quarry products per hour maintenance whilst
aggregates, chippings, boulders, quarry dust and crusher dust are produced as by
products for sale to the public.

The two plants produce high quality ballast as the main product for railway.
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Training Centre.

The TAZARA Training Centre (TTC) was constructed at the inception of TAZARA, in
1975, for the purpose of equipping In-service staff and new entrants to the Railway
Industry with skills required by TAZARA to support its operations. TTC is situated in
Mpika district in the Muchinga Province of the Republic of Zambia.
TTC conducts Railway specific training for

 Locomotive drivers
 Station masters
 Station foremen
 Train guards
 Shunters
 Pointsmen
 Permanent way (maintenance staff)
 Signaling and Telecommunications Equipment maintenance staff
Other Railway Courses offered include

 Station Accounting
 Train Conductors
 Materials Management
 Machining and Artisan Courses up to Certificate Levels

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. Construction Units

TAZARA has two Construction Units at Mpika in Zambia and Dar es Salaam in
Tanzania. These were initially established to assist in maintaining TAZARA
buildings, putting up new buildings and making roads where the Authority wants to
lay rail track instead of contracting external construction companies.

VISION AND MISSION OF A FIRM.

OUR VISION.
Our vision is to be the most preferred transport organization in the sub-region.

OUR MISSION.
To satisfy customer needs through the provision of an efficient and quality transport
service.

ORGANIZATION STRUCTURE AND MANAGEMENT OF THE FIRM.

. Administrative Structure
The Bilateral Agreement relating to the Tanzania Zambia Railway, made between
the two governments on 29 th September 1993, forms the basis and foundation of the
existence of TAZARA. This Agreement is given effect by the TAZARA Act, which
provides for the governance of the Authority, the nature of business transactions and
other matters related to the provision of services by the railway.

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The two Governments of the United Republic of Tanzania and the Republic of
Zambia hold the shares of TAZARA on a joint and equal basis. TAZARA operates as
a statutory body established by the National Legislatures of both Tanzania and
Zambia, through the TAZARA Act of 1975, amended and replaced by the TAZARA
Act of 7th July 1995.

The governance structure, as provided for by the TAZARA Act, comprise a Council
of Ministers, Board of Directors and Management.

The Council of Ministers

The Council of Ministers is the supreme policy organ of TAZARA, comprising six (6)
Ministries, three from each country respectively, i.e. the Ministers in charge of
Transport, Finance and Trade/Commerce. The Ministers responsible for Transport
are the Chairpersons of the Council in rotation between Tanzania and Zambia at the
turn of each financial year, commencing on the 1 st July and ending on the 30 th June
the following year. The Council of Ministers is required to meet at least once every
year.

. Board of directors
The Board of Directors consists of six (6) members, comprising the Permanent
Secretaries responsible for Transport from each country, two members from each
country with experience either in transport, commerce, industry or finance. The
Directors of the Board are appointed by the Ministers of Transport from the
respective countries. Except for the Permanent Secretaries who are permanent
members, the Directors hold office for a period of three (3) years after which may be
eligible for re-appointment. The two Permanent Secretaries rotate the Chairmanship
annually, i.e. 1st January. The Board of Directors is required to meet at least four
times a year.

. Management
The Managing Director is the chief executive officer of the authority and subject to
the control of the board, is responsible for the administration of the affairs of the
authority. The deputy managing director assists the managing director in the day to
day administration of the authority. The TAZARA Act stipulates that the managing
director shall be appointed from Zambia while deputy managing director shall be
appointed from Tanzania. The regional general managers, who head the regions,

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are appointed by the board of directors but supervised and controlled by managing
director.

The Executive Management Committee (EXCOM)

TAZARA’s executive committee (EXCOM) is responsible for leading the
implementation of the authority’s vision and for formulating strategies, subject to the
approval of the board of directors.

EXCOM drives and directs the day to day operations of all departments and ensures
that the whole organization works in coherent unison.

CHAPTER 2

TASK UNDER TAKEN

During this industrial practical training a lots of work were undertaken since TAZARA
workshop operates 12/7.the work was done mainly depending on the working
section that was assigned.

The following some task performing on electrical department ( PLANT AND

EQUIPMENT)

NO SECTION TASK
1 PLANT AN DEQUIPMENT I done maintenance
lather of machine control
circuit and power circuit
2 PLANT AND EQUIPMENT I replace Street lamps to
the work shop building

3 PLANT AND EQUIPMENT I done maintenance of

crane machine control
circuit and power circuit
4 I have installing Three
PLANT AND EQUIPMENT phase welding machine

5 PLANT AND EQUIPMENT I repair electric Iron, water

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Heater

Above Table show some of task that was done Plant and Equipment section

OBJECTIVE OF THE PROJECT

 The first and main objective of this project is to apply the theoretical
knowledge acquired in class to real practice so as to build competence for
students not only in class but also at practical working fields
 To enable a student to have a practical experience so as to be able to identify
different problems that occur in the electrical and electronics systems so as
to solve them.
 To build confident and competent technicians who have practical experience
of working in such fields

BRIEF DESCRIPTION OF WORK DONE

As explained above a lot of works were done on different systems but for this IPT

Report the main part that will be presented is the AUTOMATIC STAR-DELTA
MOTOR STARTER

At TAZARA workshop all repairs and services of different machines and equipment
were done at different work shops

My report cover the following parts

 What is motor starter

 Types of motor starter
 Parts of motor starter
 Automatic star – delta motor starter
 Advantages
 Working principle
MOTOR STARTER

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A motor starter is an electrical device that is used to start and stop a

motor safely. Similar to a relay,
the motor starter switches the power ON/OFF and unlike a relay, it also
provides a low voltage
and overcurrent protection. Motor starters are one of the major
inventions for motor control
applications. Also, as the name suggests, a starter is an electrical
device which controls the
electrical power for starting a motor. These electrical devices are also
used for the purpose of
stopping, reversing and protecting electric motors.

Types of Motor Starters

There are several types of motor starters. However, the two most basic types
of these electrical devices are:

Manual Starters

Manual starters are devices that are operated manually. These starters extremely
easy and straightforward to operate and do not require expert intervention. The
starter includes a button (or rotary knob) which enables a user to turn the connected
equipment on or off. The buttons feature mechanical linkages, which make the
contacts open or close, starting or stopping the motor. Thefollowing features of a
manual starter make it a preferred choice over other types:

 These starters deliver a safe, as well as economical operation.

 The compact size of these devices makes them suitable for a wide range of
applications
 They provide overload protection to the motor, protecting it from any potential
damage.
 These devices come with a vast choice of enclosures.
 The initial cost of the manual starter is low.

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MAGNETIC MOTOR STARTERS

this is the other main type of motor starter. it is operated electromagnetically. it

means that the motor load connected to the motor starter is typically started and
stopped using a lower and safer voltage than the motor voltage. just like other motor
starters, the magnetic starter also has an electrical contactor and overload relay to
protect the device from too much current or overheating.

TYPES OF MAGNETIC MOTOR STARTERS

 direct on line motor starter

 rotor resistance starter
 stator resistance starter
 auto transformer starter
 star delta starter

Component of motor starter

 contactor
 over load relay

Contactor: The main function of the contactor is to control the electric current to
the motor. A contactor can make or break power to the circuit.

Overload Relay: Overheating and drawing too much current can cause the
motor to burn out and become practically useless. Overload relays prevent this
from happening and protect the motor from any potential danger.

AUTOMATIC STAR-DELTA MOTOR STARTER

A star delta starter is the most commonly used method for the starting of a 3
phase induction motor. In star delta starting an induction motor is connected in
through a star connection throughout the starting period. Then once the motor
reaches the required speed, the motor is connected in through a delta
connection. Normally consist of three conctactors,an over load relay or circuit
breaker and timer for setting the time in the star position.(starting position) for star
delta starter, a motor must be in delta connected during a normal run and the
main purpose is to be able to use star delta starter.

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The Advantages of Using Star Delta Motor Starters:

 They are ideal for long acceleration times.

 They have a lower input surge current when compared to other starters.
 They have a simpler construction as compared to other starters

WORKING PRINCIPLE OF STAR-DELTA STARTER

This is the reduced voltage starting method. Voltage reduction during star-delta
starting is achieved

by physically reconfiguring the motor windings as illustrated in the figure below.

During starting

the motor windings are connected in star configuration and this reduces the
voltage across each

winding 3. This also reduces the torque by a factor of three.

Scheme – Working Principle of Star-Delta Starter

The Star/Delta starter is manufactured from three contactors, a timer and a

thermal overload. The

contactors are smaller than the single contactor used in a Direct On-Line starter
as they are

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controlling winding currents only. The currents through the winding are 1/root 3
(58%) of the

current in the line.

There are two contactors that are close during run, often referred to as the main
contractor and the

delta contactor. These are AC3 rated at 58% of the current rating of the motor.
The third contactor

is the star contactor and that only carries star current while the motor is
connected in star

The current in star is one third of the current in delta, so this contactor can be
AC3 rated at one

third (33%) of the motor rating

PROCEDURES AND INSTALLATION

Firstly, is to fix the electrical panel box to its required position, then: -

The mounting rail is then fixed on the panel tightened with screws.

•Mount the main and sub feeder isolation circuit breaker on the rail.

•Mount the power and control circuit fuses on the rail.

•Mount the three phase mechanically interlocked contactors on the rail.

•Mount the thermal overload on the back of the main contactor and all other two

contactors

•After fixing all accessories each to its position then connect the wires as shown
on the respective power and control wiring diagram in figure below carefully by
tightening them to avoid loose connection.

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CONCLUSION AND RECOMMENDATIONS

Conclusion:

This type of starting is used for low to medium voltage and light starting
torque motors. Itis the cheapest way to reduce the starting current and it is
in the order of 3-4 times that incase of direct online starting of induction
motor. It can be easily implemented by the relaysand the timer circuit.

The way of connecting the relays also prevents the motor from the single
phasing. The project is designed to provide low voltage start to induction
motors. This is achieved by using star to delta conversion. Star/Delta

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starters are probably the most common reduced voltage starters in the
50Hz industrial motor world. The interlocking arrangement of all the
contactor coils is traditionally wired in 440-volt AC.

Recommendation:

Compared to the reduced voltage methods it is the simple and cheapest

way of starting the motor. But it takes large in rush currents during
switching operation.

Further the project can be enhanced by using a thyristor in firing angle

control principle for soft start of the induction motor that would overcome
all the drawbacks of star delta starter.

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