PEL Report(Submitted to Engr. Hasnain Raza)

Internship & Project Report

Project Title

Energy Efficient Production Hall

Internship Department

Energy Meter Production (EMP) Department

Duration

03rd-28th August 2015

Submitted To:

Engr. Hasnain Raza

Submitted By:

Hafiz Qasim Ali (UET Taxila)

Faisal Sattar (UET Lahore)

Khubaib ur Rehman (UOL Lahore)

Muhammad Yasir (UOS Sargodha)

Zain ul Abdeen (NUML College Mianwali)

Pak Electron Limited

Page 1

Contents

Dedication…………………………………………………………………………………………………………………………4

Acknowledgement…………………………………………………………………………………………………………….5

Executive Summery…………………………………………………………………………………………………………..6

History & background of PEL………………………………………………………………………………………….…7

Appliances Division………………………………………………………………………………………………….……….7

Power Division……………………………………………………………………………………………………………..….7

Structure of EMP Departmen ………………………………………………………………………………….....…..8

Energy Meters………………………………………………………………………………………………………………...9

Single Phase Energy Meters……………………………………………………………………………………….……9

SMT (Surface Mounting Technology) ………………………………………………………………………..……9

Terminal Block Assembly……………………………………………………………………………………………..…10

Final Assembly……………………………………………………………………………………………………………….10

Testing & Calibration………………………………………………………………………………………………..……11

Parameter Setup…………………………………………………………………………………………………….…….13

OPEN Enable……………………………………………………………………………………………………………..….13

SPDP (Security Packing & Dispatching) ……………………………………………………………………..…13

Quality Control…………………………………………………………………………………………………………….14

Dispatch packing……………………………………………………………………………………………………..….14

Sample Testing…………………………………………………………………………………………………………...14


Page 2

Contents

PEL INTERNSHIP PROJECT………………………………………………………………………………………………….15

Project title……………………………………………………………………………………………………………………….15

Objective………………………………………………………………………………………………………………………….15

Components required……………………………………………………………………………………………..…….….15

LED Light Specifications…………………………………………………………………………………………….….….16

Designing of Lightening Scheme maintaining 100Lux at table surface………………………….…17

Room Dimensions……………………………………………………………………………………………………..…….17

Calculating No. of Luminaries……………………………………………………………………………….……..…17

Mounting Scheme……………………………………………………………………………………………….………….18

Circuit Diagram……………………………………………………………………………………………….………….….19

Block Diagram…………………………………………………………………………………………….……….………..20

PCB Layout……………………………………………………………………………………………………………….……20


Page 3

Table of Figures

Figure 1: Structure of EMP Department………………………………………………………………………….8

Figure 2: 1 Watt DIY LED………………………………………………………………………………………………..16

Figure 3: Lightening Scheme………………………………………………………………………………………….18

Figure4: Circuit Diagram…………………………………………………………………………………………….…19

Figure 5: Block Diagram………………………………………………………………………………………………..20

Figure6: PCB Layout………………………………………………………………………………………………………20


Page 4

DEDICATION

Dedicated to our respected coordinators at PEL and all those who helped us out to make our

Internship full of learning


Page 5

Acknowledgement

We are really pleased here to acknowledge the sheer efforts of many people those who have provided us

their relentless services in the completion of our Internship and our internship report. We would like to thank

personally to all EMP department Engineers Mr. Hasnain Raza & Mr. Hassan Ali who from their very busy

schedule helped us a lot in my learning program. Also we would like to thank to Mr. Hasnain Abid (HR) &

Miss Fatima (HR) who cooperated and guided us very well throughout this period.

May Allah Bless you all!


Page 6

Executive summary

We started our internship at PEL on 3rd August 2015. We were expecting a huge learning from this experience as this was first time we stepped into real world of manufacturing products. We were enthusiastic and full of energy to learn and explore the facility. We thank whole heartedly to those who made this internship possible. We cannot express our gratitude for our supervisor and engineers at EMP department who showed by example how to be professional and work toward the success of the company. Despite all the short comings experience at PEL was a fruitful one and we learned a lot. We would also like to thank those who took out time form their busy schedule to explain the working and assembling of Energy meter. No company is perfect, every company lacks in one area or the other but the thing is only those companies remain in competition who by all means keep on improving on their already perfect systems. We wish PEL and all its employees a very best of luck for their future and may PEL become a flag bearer of the manufacturing industry in Pakistan.


Page 7

History and Background of PEL

Pak Elektron Limited (PEL) is the pioneer manufacturer of electrical goods in Pakistan. It was established in 1956 in technical collaboration with M/s AEG of Germany. In October 1978, the company was taken over by Saigol Group of Companies. Since its inception, the company has always been contributing towards the advancement and development of the engineering sector in Pakistan by introducing a range of quality electrical equipment and home appliances and by producing hundreds of engineers, skilled workers and technicians through its apprenticeship schemes and training programs. The company comprises of two divisions:

Appliances Division Power Division

APPLIANCES DIVISION

This Division of PEL consists of appliances manufacturing. Following appliances are being manufactured at PEL:

PEL Air Conditioners

PEL Refrigerators

PEL Deep Freezers

PEL Microwave Ovens

PEL Water Dispensers (Research)

POWER DIVISION

PEL was founded in 1956 and has since been serving the Power utilities, industries, individual customers, housing and commercial projects by providing reliable, customized and cost effective solutions. Following power utilities are manufactured at PEL at the moment:

Power Transformers

Switchgears

Energy Meters

Distribution Transformers Since I have done my internship in Energy Meter Production department, so here I shall explain it in detail.


Page 8

Structure of EMP Department:

Energy meter is assembled here and have to pass through various sections and processes to

come to final form. Here is given the flow layout of various sections of Energy meter

department (EMP).

Figure 1: Structure of EMP Department


Page 9

Energy Meters

Following type of Energy meters are being manufactured and assembled at PEL at the moment:

Single Phase Energy meters

Three Phase Energy meters

LT & HT meters

Single Phase Energy meters Each energy meter is assembled and passes through various processes in different blocks of the EMP department. Following are the main working blocks in EMP department:

SMT (Surface Mount Technology)

Terminal Block

Final Assembly

Calibration & Accuracy

SPDP (Security Packing & Dispatching)

Quality Control

SMT (Surface Mounting Technology) PCB with few minor components like capacitors, resistors and pre-programmed microcontroller already installed is provided here. Following components are being installed/ assembled over here:

Battery Placement

Battery soldering

LCD pinned

1 LED fixed

Complete Soldering

Micro switch

Remaining 2 LEDs fixed

Micro switch soldering

Transmitter receiver are connected

Unnecessary extended legs are cut down

Visual inspection of front and back of PCB

Visual inspection is performed to check whether all the components are connected properly. If yes, then PCB is sent to final assembly section where it is assembled in base. CT & PT are already assembled in base and are connected with PCB’s appropriate points.


Page 10

Terminal Block Assembly

In this section, copper wire is cut. Also Resistance metallic sheets are manufactured and finally all these are sent to be soldered with CT & PT in the base. Following steps are being performed over here:

Cu wire is covered with PVC insulation sleeve

Resistance metallic sheet is soldered with pressure plate

Solder three wires

Glass sleeve

Current coil sleeve/shrinkable sleeve

All sleeves are compressed by hot air

Cu rope wire (Neutral) is connected with CT

Phase rope wire is connected with PT

CT & PT are coupled and combined

Both CT & PT are fixed in base

Screw block is connected with base

Base is visually checked

Small errors are removed by hand

Final Assembly Terminal block base with CT & PT and PCB from SMT are sent in final assembly section. Both are coupled here. Following stages are involved in doing so:

Cable tie

PCB soldered with base here

Error check Following errors are monitored and checked here. Minor errors are removed here while for serious sort of errors, the defected part is sent to the concerned section

Cable Tie checked

Wires are checked if they are properly connected or not

Wire placement check

Switch checking

Terminal block check

LCD is checked and it is supposed to give zero, if not, then error is removed

If everything is OK and no fault or error is found anywhere in meter, then meter is sent to calibration and verification section.


Page 11

Testing & Calibration

Following procedures are performed on meter in this section to check and remove any sort of error in meter:

Calibration (9 steps)

Accuracy

Parameters

Calibration

Following 9 steps of calibration are performed on meter:

Step No.1 Assign Meter No. First of all, meter no is given to each meter.

Step No. 2 Temperature Calibration Temperature is maintained and calibrated at 23 Degree Celsius

Step No. 03 Live Percentage Error In this step, meter is tested with following conditions applied PF=1 Current=10A Voltage=ON (Phase) Range is -0.29 to 0.29

Step No. 04 Live Percentage Error with Induction Load Following conditions are maintained in this step: Current=10A PF=0.5L

Step No. 05 Resistive Load Live Percentage Error Meter is tested and calibrated under these conditions: Current=1A PF=Unity


Page 12

All of the above 5 five tests are performed under two wire system. For one wire system, following test is performed:

Step No. 06 One Wire Phase This test is performed under following conditions: Current=1A PF=Unity Voltage=Off

Step No. 07 Neutral Percentage Error Following specifications are considered in this step: Current=1A PF=Unity Voltage=ON

Step No. 08 NPE (Neutral Percentage Error) This test is performed under following conditions: Current=10A Load=Inductive PF=0.5L

Step No. 09 Neutral (Voltage Off) This is the last step of calibration. For meter to be perfect it has to pass all the nine steps of calibration or it is disqualified and sent back for recycling Following conditions are applied in this step: Current=1A PF=Unity Voltage=OFF


Page 13

Accuracy

After calibration, each meter’s accuracy is checked as per costumer requirement. Normally a range of -0.5 to 0.5 is considered OK. Voltage is kept ON in checking accuracy.

Full Current Accuracy In this step, a meter is given its full current rating and its working is verified. Normally a full load rating for single phase meter is 40A. So, a load of 40A is applied and accuracy is checked at full load.

Parameter Setup Install the program and verify the ‘Display Parameters’ on LCD. Following parameters are verified and have to appear accurately on LCD Display:

Parameter Time

KESL No. 5s

KWh Rating 10s

Previous month maximum demand 5s

Instantaneous Power 5s

Current rating 10s

OPEN Enable After Calibration and accuracy is verified, the last step performed in this section is Security. In this section, micro switch is programmed so that if any customer tries to temper the meter, then ‘OPEN’ is displayed on LCD and it cannot be undone until meter is re-programmed in Industry.

SPDP (Security Packing & Dispatching) In this section meter’s security is considered implemented and then after verification in Quality Control Section, it is sent for dispatching. But this section is considered as one so it is called as SPDP. Following stages are performed in SPDP Section:

LCD Screen protector is removed

Even & Odd table distribution

Terminal tight

Loose screw tight

Rubber Gas kit


Page 14

Top cover fixing

Lead seal fixing

Printing Serial No

Base Plate welding (6 bar pressure)

Top Cover Seal punching

Top lid welding

Quality Control

After security is being implemented on meter, then meter is sent to quality control section to verify the proper working of meter. Same steps as of Calibration section are performed on meter to verify the proper working. If meter fails any of the test, it is disqualified and sent back for recycling.

Quality control Section include following steps of verification

Software verification

Electrical verification

Visual inspection

Dispatch Packing

When the meter working is verified then it is sent for dispatching where meter are packed and collected in lots and are ready to send to customer.

Sample Testing

When the meter are packed and are ready for delivery to customer, then normally from each lot of 1000 meters, 10 are randomly selected by customer and are asked for testing. Further 10 tests on each sample are performed and each sample has to pass all of them. In any case, if a single sample fails any test, then the whole lot is rejected by WAPDA or any customer and meters have to be reoffered.


Page 15

PEL INTERNSHIP PROJECT

Project Title

Energy Efficient Production Hall

Objective

Replace the present lightening system of EMP department office by LED Lights. Consume Less Power as per present system Maintain 100Lux at table height anywhere in office Design Lightening Scheme

Components/Equipment Required Following components are used in the design of circuit: AC Supply 220V Step Down Transformer (220V to 12V) Diodes (Bridge Rectifier) for DC Conversion Inductor (12mH) Capacitor (470uF) 12V LEDs

LEDs used here are in sets of 3LEDs which consume about 5Watt each set and give us about 300 lumens. From now onward in this project we will use the word Luminary for Each set of 3LED strips/bulb.


Page 16

LED Light Specifications:

For the designed scheme LED lights are used as set of 3 LEDs which rated at 5Watt and will

give us 300 lumens each unit.

Following LED light panel will help to make an idea about it:

Figure 2: DIY 1 Watt LED

Name DIY

Brand Lighthouse LEDs

Model 1 watt star LED

Current 350mA

Size 1 Watt star LED

Lens Color Clear/Diffused

Lumens per LED 80-90 lumens

Operating Voltage 12V dc

Country of manufacture United States

Color Warm/Soft white

Price $ 6.99


Page 17

Designing of Lightening Scheme maintaining 100Lux at table surface Room Dimensions Length=10ft Width=10ft Height=12ft Now we shall design the lightening scheme of the office room of given dimensions. In doing so we have to maintain 100Lux on table and so we have to find how many luminaries of 5Watt each are required so that our room is properly lighted up.

(Since we considered the table height as 2 feet which is our work plane) (Takes into effect light loses in terms of absorption, reflection etc.) Normally utilization for different work places is as follows:

Calculating No. of Luminaries Using Lumens ‘rule for number of Luminaries:


Page 18

Taking Lightening Loss factor as one i.e. No depreciation over life

Approximately to 4

So No of 4Watt luminaries required to maintain 100Lux are 04.

Mounting Scheme

Since Room distribution is even in both axes, so making a grid of 2:2 will provide us uniform

light of 100Lux throughout our work plane. Lightening Scheme is given below:

Figure 3: Lightening Scheme

Mounting Height

Working Plane

2 feet

12 feet


Page 19

Circuit Diagram: The circuit used for designing this scheme is designed on Circuit Wizard and is given below:

Figure4: Circuit Diagram


Page 20

Block Diagram

The block diagram of the scheme is as follows:

Figure 5: Block Diagram

PEL Report(Submitted to Engr. Hasnain Raza)

Documents

Transcript of PEL Report(Submitted to Engr. Hasnain Raza)