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Final Report 2013

Internship Final Report

6 weeks working experience in power house

Submitted by
Muhammad Ammad Electrical Engineering 6th semester duration from 23rd July ,2013 to 2nd Sep , 2013

Submitted to
Haier Pakistan and Ruba Mr. Tallat ( head of power house)

1. Introduction to Haier 1.1. Manufactured Products 1.2. Summary of the Products 2. Power System 2.1. Introduction to Power System 2.2. Equipments installed in Power House 2.3. Rating of the Equipments 3. Basic definition of Electrical System 3.1. Volts 3.2. Amperes 3.3. Hours Power 3.4. Motor 3.5. Generator 3.6. Synchronization 3.7. Condition of Synchronization 3.8. Methods for Synchronization 3.9. Reactive Power 3.10. Active Power 3.11. Apparent Power 3.12. Power Triangle 3.13. Power Factor 3.14. Methods to Improve the Power Factor 4. Diesel Engine 5. Gas Engine 6. Air Compressor 7. Cooling Tower 8. Transformer 9. Control Panels 10. Conclusion

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Haier: A Global Brand Haiers strategy is to continue providing innovative consumer requirement met and quality products and services that bring value to its consumers around the world in times of global economic difficulties contributed to this success. Haiers main competitors market shares in major home appliances, refrigeration appliances and home laundry appliances have generally declined, while Haiers market share increased in all categories. Euro monitor International; the world's leading independent provider of business intelligence on industries, countries and consumers, at December announced Haier has ranked No.1 in Global Major Appliances Brands ranking by brand shares and has announced Haier Group as leading business intelligence firm in the world. Haier Production Facility in Pakistan Anticipating the vast potential of Pakistani market, Haier has set up a stateof-the-art industrial park at Raiwind Road Lahore. The production plant spreads over a vast area of 63 acres with a covered area of 0.6 million square feet including a workers colony. This production facility has the capacity to produce over 1 million pieces of white goods per annum. Since production began in June 2002, the Pakistans domestic market has increased rapidly. Haier Pakistan: A Symbol of Operational Excellence Haier Pakistan is a strong evidence of Pak-China relationship. The joint venture between Ruba General Trading Company and Haier group of China brought Haier into Pakistan eight year ago. Haier Pakistan is operating in the Pakistani market with a commitment to help its consumers reap the benefits of modern lifestyle and unmatched nationwide customer support. Haiers vision is to improve the standards of life throughout Pakistan by offering high quality, consumer requirement met products with innovative features aimed directly to make its users life easier, enjoyable and yet affordable. Haier believes that the essence of globalization is localization. For Haier, this means a Three-in-One

operational framework: complete localization of design, manufacture, and marketing. Haier aims to use local financing and employees to become a part of the local community while creating a global brand. Haier Pakistans Nationwide Network 1,000 sales outlets, 15 large experience shops, 305 exclusive shops, 17 service centers, more than 120 service outlets, a call service centerhad been established in Pakistan besides the amazingly improved marketing network too. Haier Pakistans steady after sale service network always stands in front to supply the most convince service. Haiers Achievement in Pakistan Haier Pakistan has the overall market share of 17.5 % in Pakistan and Haier ranks 2nd in the home appliances market in Pakistan, Air conditioner ranked No.1, Wash Machine ranked No.1 and Refrigerator ranked No.2 in Pakistan market. Haier has the capacity to produce 3,000,000 units of all product categories in Pakistan. Products portfolio of Haier Pakistan have been rapidly expanded from the original refrigerators, air conditioners, washing machines to Deep freezers, commercial air conditioners, televisions, LCD TVs, LED TVs, microwave ovens, and other 10 series even over 100 models including the entire category of domestic appliances that deals in irons, toasters, sandwich makers, DVD players etc. Conclusion Haier is a leading global brand that recognizes and respects the realities and circumstances of its customers and responds to these by rewarding them with inspiring solutions they can always rely on. Haier comes from the belief that progress lies in continued technological advancement in order to make customers lives easier, more efficient and more productive and it will continue making all the efforts to excel in the market. As Haier is moving towards Eco-Life which will be very effective in making customers life more convenient in terms of products usage & efficiency.


Manufactured Products
Washing Machine Air Conditioner Refrigerator Freezer Microwaves Oven LCD Small domestic applications


Summery of the Products

Washing Machine :Energy Efficiency Rating Higher energy ratings means higher energy savings for you and your family Wave drum The design of the high quality drum creates waves of water to take better care of your textiles, avoiding any damages while giving the maximum washing performance Anti Bacterial Treatment Haier gaskets are specially made with Haier Anti-bacterial treatment to prevent bacteria from forming, making the washing environment more hygienic and clean. Certain models have dispensers equipped with the same technology. Double Drive technology The frist ever company to develop the double drive technology to avoid the twist of the couthes. Double protect your clothes. Zero carbon to make her quite silence Combined with the GE company to develop the converence technology to make the washing to be eco-clean.

AIR CONDITIONER:DC inverter Haier DC inverter Air Conditioner adopts the advanced 180 sine weave DC inverter driving technology and multi-step of speed control. More energysaving, more consistent, and much quiet than fix-speed air conditioners. I Feel You By detecting number and location of people in the room, air flow, air speed and temperature can be adjusted automatically. Precise System Control Technology with temperature monitor in air conditioner area and electrical expansion valve control, the chips will adjust the status of super cooling and overheating to different situation and different combination. Active PFC Technology Improve the efficiency of power using to 99%. Lift the voltage of main wire, and make compressor works stably.

Refrigerator & Freezer :Eco Friendly Haier refrigerators are eco-friendly in nature with salient features like silent operation, low energy consumption, Non-toxic materials, recyclable parts No Frost technology ensures that the freezer section remains frost free and provides better cool air distribution throughout the refrigerator. Maintenance has never been easier! Fast Cooling With 5-side Evaporator Design Fast cooling system with 5-side evaporator design to ensure stable performance Super fast cooling Haier optimize cooling system ensure quick cooling,1.5L water can be made into ice in 2.5h. Water & Ice Dispenser dispenser provides you with clean filtered water and cubed or crushed ice whenever you want. Now, the entire family can enjoy fresh water and ice at any time Oil Cooling Compressor With oil cooling technology, more reliable & steady Wider voltage design Stable performance with wider voltage design

Microwave Oven :Special Cavity Design Lattice hearth cavity design microwave can be reflected regularly, then can be absorbed by foods fully ,saving energy , giving you an ECO life. High Efficient Heating System with Whirlwind Whirling wind in an arc makes heat circulate adequately around the food and your food will be heated evenly

Small Domestic Appliances :-


POWER SYSTEM :2.1 Introduction to Power System

An electric power system is a network of electrical components used to supply, transmit and use electric power. An example of an electric power system is the network that supplies a region's homes and industry with power - for sizable regions, this power system is known as the grid and can be broadly divided into the generators that supply the power, the transmission system that carries the power from the generating centres to the load centres and the distribution system that feeds the power to nearby homes and industries. Smaller power systems are also found in industry, hospitals, commercial buildings and homes. The majority of these systems rely upon threephase AC power - the standard for large-scale power transmission and distribution across the modern world.



Equipments installed in Power House

Diesel Engine Gas Engine Air Compressor Air Cooling Tower Transformer Control Panels

2.3 Rating of the Equipments

Diesel Engine

Rating : 3 Phase ~440V ( L-L ) & ~220V( L-N ) 1800 rpm 0.97 p.f lag 1 MW 50 Hz


Gas Engine

Rating : 3 Phase ~440V ( L-L ) & ~220V( L-N ) 1800 rpm 0.97 p.f lag 1 MW 50 Hz Air Compressor

Rating : I/P ~400v & 226 amp Compress air upto 8.2 bar Cool air temperature 2.2C Relative Humidity 10%



Rating : 3 phase Rated power 2500 kVA Rated frequency 50 Hz Total weight 6400 kg Oil weight 1475 kg Ambient Temp 50 C Total 30334W Rated Voltage at no load 1100V (HV) & 415V (LV) Rated current 131.2 amp (HV) 3478amp (LV) Impedance Voltage 7.18% Winding temperature rise 55 C Duration of short circuit 3 sec


Cooling Tower

Control Panels


3. Basic definition of Electrical System 3.1 3.2 Volts :Amperes:-

The electrical force or pressure that causes current to flow in a circuit. Voltage is measured in volts. The ampere is the base SI unit of electrical current. The ampere is defined as the amount of electrical current required to maintain a force of 2 x 10-7 Newtons per meter between two infinitely long parallel wires of negligible cross section held one meter apart.



Horsepower is defined as the power that a horse gives when pulling, and it is used informally to mean power, or is the power needed to raise 550 pounds a distance of one foot in one second or the power needed to move 33,000 pounds a distance of one foot in one minute.

3.4 3.5 3.6


a device that converts electrical energy to mechanical torque.

a device that converts mechanical energy to electrical energy .

Synchronizing a generator to the power system must be done carefully. The speed (frequency) and voltage of the isolated generator must be closely matched, and the rotor angle must be close to the instantaneous power system phase angle prior to closing the generator breaker to connect the isolated generator to the power system.



Condition of Synchronization:There are five conditions that must be met before the synchronization process takes place. The alternator must have equal line voltage, frequency, phase sequence , phase angle and waveform to that of the infinite bus.


Methods for Synchronization:In the past, synchronization was performed manually using three-lamp method. Nowadays, the process is automatically operated and controlled with the aid of synch relays and micro-electronic systems


Reactive Power :reactive loads such as inductors and capacitors dissipate zero power, yet the fact that they drop voltage and draw current gives the deceptive impression that they actually do dissipate power. This phantom power is called reactive power, and it is measured in a unit called Volt-Amps-Reactive (VAR), rather than watts. The mathematical symbol for reactive power is (unfortunately) the capital letter Q .

3.10 Active Power :The actual amount of power being used, or dissipated, in a circuit is called true power, and it is measured in watts (symbolized by the capital letter P, as always)

3.11 Apparent Power :The combination of reactive power and true power is called apparent power, and it is the product of a circuit's voltage and current, without reference to phase angle. Apparent power is measured in the unit of VoltAmps (VA) and is symbolized by the capital letter S.


3.12 Power Triangle :-

3.13 Power Factor :The power factor of an AC electric power system is defined as the ratio of the active (true or real) power to the apparent power PF = cos PF = P / S where PF = power factor P = active (true or real) power (Watts) S = apparent power (VA, volts amps)

3.14 Methods to Improve the Power Factor : Improving the power factor of an installation requires a bank of capacitors which acts as a source of reactive energy. This arrangement is said to provide reactive energy compensation. Minimize operation of idling or lightly-loaded motors.


Avoid operation of equipment above its rated voltage. Replace standard motors as they burn out with energy-efficient motors. Power factor is also significantly affected by variations in load. A motor must be operated near its rated capacity to get the highest power factor.

4. Diesel Engine
Diesel engine that is installed in Haier s utility department (power house)


Working Construction and its Principle Air Inlet System After cooler core, corrosion resistant coated (air side) Air cleaner, regular duty with service indicators Turbochargers, rear mounted Control System Governor, RH, 3161 with self contained synthetic oil sump. Air-fuel ratio control, mechanical speed control, without torque control. Governor control, positive locking Cooling System Thermostats and housing for conventional core radiator Jacket water pump, gear driven, centrifugal Exhaust System Exhaust manifold, dry Flywheels and Flywheel Housings Flywheel , SAE No. 00, 183 teeth Flywheel housing, SAE No. 00 Fuel System Fuel filter, with service indicators, cartridge type with RH service Fuel transfer pump Instrumentation Instrument Panel, RH Engine oil pressure gauge Fuel pressure gauge Oil filter differential gauge Jacket water temperature gauge Service meter, electric Tachometer Lube System Crankcase breather, top mounted Oil cooler Oil filler and dipstick, RH Oil pump Oil filter, cartridge type with RH service Shallow oil pan


Mounting System Rails, mounting, engine length, 254 mm (10 in), industrial-type, C-channel. Power Take-Offs Accessory drive, upper RH Front housing, single sided Protection System Junction box Manual shutoff, RH Safety shutoff protection, energized to shutdown Low oil pressure, low idle 69 kPa (10 psi); high idle 207 kPa (30 psi) Water temperature Over speed 3161 governor solenoid energized to shutdown Starting System Starting switch General Paint, Caterpillar Yellow, Vibration damper and guard, Lifting eyes Diesel Cycle


5. Gas Engine

1000 KW Jenbacher J320 Gas Generator Set 400 Volt, 1500 rpm, 50 HZ, Year: 2006, Fuel: Natural Gas, 35,000 hrs, Service was completed by Jenbacher at 30,000 hrs. includes circuit breaker, radiator, panels, all the fittings, manual and records. Excellent Good Condition and well maintained Note : Working same as a diesel engine the difference is that Natural gas is used in this generator.

6. Air Compressor
External body of the air compressor


Internal body of the air compressor

Working Principle :Take a air from its surrounding and compressed the air upto 8.2 bar which cause heating effect which becomes hot air then passed towards the air dryer , air dryer cool the air upto 2.2C and store it which is used in the required purpose.


7. Cooling Tower :-

Principle :A cooling tower is a heat exchanger, inside of which heat is withdrawn from the water by contact between the water and the air. The heat transfer occurs through the heat exchange between air and water and through the evaporation of a small part of the water that needs to be cooled. This will allow to cool down to a temperature lower than the ambient temperature, which is an important advantage compared to dry coolers. Consequently, a cooling tower is not a chimney producing smoke. The mist which can be seen above a cooling tower is regular steam with the same composition as a normal cloud.


8. Transformer

Step up transformer step-up transformer that boosts a low voltage into a high one

9. Control Panels
All the electrical and mechanical equipments are controlled in each panel these panels are connected with engines then each department of the haier such as distribution of electricity in A.C hall , W/M hall etc are distributed and controlled through panels


10. Conclusion
Experience getting from haiers utility department ( power house) was very good , and summery of my experience is in the form of block diagram , which is to understand for every one . Air Compressor Fresh air filter air compressor air dryer cool air Distribution and transmission


diesel engine



Control panels 2500kva T/F