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
Wearereallypleasedheretoacknowledgethesheereffortsofmanypeoplethosewhohaveprovidedus
theirrelentlessservicesinthecompletionofourInternshipandourinternshipreport.Wewouldliketothank
personallytoallEMPdepartmentEngineersMr.HasnainRaza&Mr.HassanAliwhofromtheirverybusy
schedulehelpedusalotinmylearningprogram.AlsowewouldliketothanktoMr.HasnainAbid(HR)&
MissFatima(HR)whocooperatedandguidedusverywellthroughoutthisperiod.
MayAllahBlessyouall!

Page 6
Executivesummary
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
ThisDivisionofPELconsistsofappliancesmanufacturing.Followingappliancesarebeingmanufacturedat
PEL:
 PELAirConditioners
 PELRefrigerators
 PEL Deep Freezers
 PEL Microwave Ovens
 PEL Water Dispensers (Research)
POWER DIVISION
PELwasfoundedin1956andhassincebeenservingthePowerutilities,industries,individualcustomers,
housingandcommercialprojectsbyprovidingreliable,customizedandcosteffectivesolutions.Following
powerutilitiesaremanufacturedatPELatthemoment:
 PowerTransformers
 Switchgears
 EnergyMeters
 DistributionTransformers
SinceIhavedonemyinternshipinEnergyMeterProductiondepartment,sohereIshallexplainitindetail.

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)

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