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

Dedication4

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

Pak Electron Limited

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

Pak Electron Limited

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 Layout20

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Page 4

DEDICATION

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

Internship full of learning

Pak Electron Limited

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!

Pak Electron Limited

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.

Pak Electron Limited

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.

Pak Electron Limited

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

Pak Electron Limited

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 PCBs appropriate points.

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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.

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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 cali