1. The internship report summarizes the internship of three students in the maintenance department of Atlas Honda Limited. 2. The report describes the existing power system and power factor correction units at the Karachi and Sheikhupura plants. It analyzes power consumption data and calculates voltage, current, power factor, KVA, KW, and KVAR readings. 3. The report concludes that the existing power system and power factor units are meeting the current needs of the plants and working efficiently.

1. THE INTERNSHIP REPORT
TEAM MEMBERS
1. MUHAMMAD ZUBAIR SHABBIR
2. WAQAR ULLAH SHAH
3. MUHAMMAD FAHEEM ALI
DEPARTMENT: BE ELECTRICAL
ADVISER: SYED SAJJAD ALI (MAINTENANCE)

2. ABSTRACT
We have given the task to observe the current situation of power systemand power factor unit
and take out all the necessary readings which help the maintenance department to manage
their plant power consumptions.
INTRODUCTION
Atlas Honda Limited (AHL) is a joint venture between the Atlas Group and Honda Motor Co.
Ltd., Japan. The company was created by the merger of Panjdarya Limited and Atlas Autos Ltd.
in 1988. Both these motorcycle manufacturing concerns were established by the Atlas Group.
AHL is playing a pioneering role in creating conditions for easy and confident use of motorcycles
all over the country. A vast and growing network of over 1600 sales service and spare parts
dealers has been established
KARACHI PLANT
Company mother plant is based in the city of lights and provincial capital of Sindh , The Karachi
city. It is located at F-36, Estate Avenue, S.I.T.E. Karachi. Atlas Group signed technical
agreement with Honda in 1963 and plant started commercial production subsequently. Plant
spread over an area of 5 acres. In 1964, production began with 7 motorcycles per day. Now
plant production has reached to 300 units in a day. Plant manufactures CD 70 only.
SHEIKHUPURAPLANT
Another plant is situated in Sheikhupura city, Punjab. It is located at 26-27 KM Lahore-
Sheikhupura Road Sheikhupura. The plant was built in 1981 and spread over an area of 27 acres
with the establishment of modern and synchronized 500K plant in 2006. The plant
manufactures all four models i.e. CD 70, Pridor, CG 125 and CG 125 Deluxe.
Annual ProductionCapacity AuthorizedCapital Paid Up Capital
750,000 1.5 Billion (Rupees) Rs. 1,034.066 Million

3. MAINTENANCE DEPARTMENT
The maintenance department is responsible to maintain working of all types of machine and
supply electricity to all departments, compress air to all pneumatic and hydraulic machines and
steam to buffing shop.
EXISTING SYSTEM AND OPERATION
HT Room
K-Electric supply of two 11KV lines F36 and F10. Both HT lines connected with energy meter
and then connected main vacuum circuit breaker. F36 split into two F36A and F36B both
connected with separate VCB and OCB respectively then supply goes to transformer.
Transformer Room
F36 A is connected with 1500 KVA transformer Siemens.
F36B is connected with 1500 KVA transformer Siemens.
F10 is connected with 1000 KVA transformer Johnson and Philips.
Transformer temperature is maintained at 45oC.
And then supply goes to LT Room.
LT Room
All 3 LT supply is connected with separate PFI controller (Technologic Reactive Power Controller
650).
F36A PFI unit has 6 capacitive banks of 50 KVAR ratings. All six are automatic.
F36B PFI unit has 6 capacitive banks 50 KVAR ratings. One manual and 5 automatic.
F10 PFI unit has 12 capacitive banks 50 KVAR rating. Two manual, 4 off and 6 automatic.
Distribution
F36A is fixed for welding shop, press shop and compressor.
Rest of all load can be connected with either F36B or F10.
The temperature of main supply cable is 37OC, 38OC.
Load Management:
The maximum load according to our observation on (2-8-2016) PEAK WORKING TIME.
TRANSFORMER CURRENT VOLTAGE P.F
F36A 800 TO 1200 A 440V 0.96
F36B 500 TO 550 A 440V 0.94
F10 480 TO 520 A 440V 0.96

4. Calculation
F 36A
VA = 3 × 1200 × 440/√3 = 914 kVA
W = 914 × .96 = 877 kW
𝑉𝐴𝑅 = √914𝐾𝑉𝐴2 − 877𝐾𝑊^2 = 260𝐾𝑉𝐴𝑅
F36B
𝑉𝐴 = 3 × 550 ×
440
√3
= 419𝐾𝑉𝐴
𝑊 = 419𝑘 × 0.94 = 393𝐾𝑊
𝑉𝐴𝑅 = √419𝐾2 − 393𝐾2 = 150𝐾𝑉𝐴𝑅
F10
𝑉𝐴 = 3 × 520 ×
440
√3
= 396𝐾𝑉𝐴
𝑊 = 396𝐾 × 0.96 = 380𝐾𝑊
𝑉𝐴𝑅 = √396𝐾2 − 380𝐾2 = 112.46𝐾𝑉𝐴𝑅
POWER FACTOR CORRECTION
Powerfactorcorrection isthe termgiventoa technologythathasbeenusedsince the turnof the 20th
centuryto restore the powerfactorto as close to unityas iseconomicallyviable.Thisisnormally
achievedbythe additionof capacitorstothe electrical networkwhichcompensate forthe reactive
powerdemandof the inductive loadandthusreduce the burdenonthe supply.There shouldbe no
effectonthe operationof the equipment.Toreduce lossesinthe distributionsystem,andtoreduce the
electricitybill,powerfactorcorrection,usuallyinthe formof capacitors,isaddedtoneutralize asmuch
of the magnetizingcurrentaspossible.Capacitorscontainedinmostpowerfactorcorrectionequipment
draw currentthat leadsthe voltage,thusproducingaleadingpowerfactor. If capacitorsare connected
to a circuit thatoperatesat a nominallylaggingpowerfactor,the extentthatthe circuitlagsisreduced
proportionately.Typicallythe correctedpowerfactorwill be 0.92 to 0.95. Some powerdistributorsoffer
incentivesforoperatingwithapowerfactorof betterthan 0.9, for example,andsome penalize
consumerswithapoor powerfactor.There are manyways thatthisis meteredbutthe netresultisthat
inorder to reduce wastedenergyinthe distributionsystem,the consumerisencouragedtoapplypower
factor correction.MostNetworkOperatingcompaniesnow penalize forpowerfactorsbelow 0.95 or 0.9.
KVAR
KVA
KW

5. WHY IMPROVE POWER FACTOR ?
The benefitsthatcanbe achievedbyapplyingthe correctpowerfactorcorrectionare:
 Environmental benefit.Reductionof powerconsumptiondue toimprovedenergyefficiency.
Reducedpowerconsumptionmeanslessgreenhouse gasemissionsandfossil fueldepletionbypower
stations.
 Reductionof electricitybills
 Extra KVA available fromthe existingsupply
 Reductionof I^2 R lossesintransformersanddistributionequipment
 Reductionsof voltage dropinlongcables.
 Extendedequipmentlife–Reducedelectrical burdenoncablesandelectrical components.
HOW TO IMPROVE POWER FACTOR
Powerfactorcorrectionisachievedbythe additionof capacitorsinparallel withthe connectedmotoror
lightingcircuitsandcan be appliedatthe equipment,distributionboardorat the originof the
installation.Staticpowerfactorcorrectioncanbe appliedateachindividual motorbyconnectingthe
correctioncapacitorsto the motor starter.A disadvantage canoccur whenthe loadonthe motor
changesand can resultinunderor overcorrection.Staticpowerfactorcorrectionmustnot be appliedat
the outputof a variable speeddrive,solidstate softstarterorinverterasthe capacitorscan cause
seriousdamage tothe electroniccomponents.Over-correctionshouldnotoccurif the powerfactor
correctioniscorrectlysized.Typicallythe powerfactorcorrectionforan individualmotorisbasedonthe
nonload (magnetizing) powersince the reactiveloadof amotor iscomparativelyconstantcomparedto
actual kW loadovercompensationshouldbe avoided.Care shouldbe takenwhenapplyingpowerfactor
correctionstar/deltatype control sothat the capacitorsare not subjectedtorapidon-off-onconditions.
Typicallythe correctionwouldbe placedoneitherthe Mainor Deltacontactor circuits.Powerfactor
correctionappliedatthe originof the installation consistsof acontrollermonitoringthe VAr’sandthis
controllerswitchescapacitorsinoroutto maintainthe powerfactorbetterthana presetlimit(typically
0.95). Where ‘bulk’powerfactorcorrectionisinstalled,otherloadscanintheorybe connected
anywhere onthe network.
VACUUM CIRCUITBREAKER
Circuitbreakersmustmake andbreakall currentswithinthe scope of theirratings,fromsmall inductive
and capacitive loadcurrentsupto the short-circuitcurrent,andthisunderall faultconditions inthe
powersupplysystemsuchasearthfaults,phase oppositionandsoon.
CONCLUSION
We have concluded thatexistingpowersystemandpowerfactorunitmeets the currentrequirementof
the whole plantandworkingefficiently.