PEL Report(Submitted to Engr. Hasnain Raza)

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

  • Internship & Project Report

    Project Title

    Energy Efficient Production Hall

    Internship Department

    Energy Meter Production (EMP) Department


    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




    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



    Project title.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

  • Pak Electron Limited

    Page 4


    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


    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


    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)


    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


    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.

  • Pak Electron Limited

    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.

  • Pak Electron Limited

    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)




    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