Service Industries Limited, Gujrat

Title:
Internship Report

Submitted to:
HR Department

Submitted By:
Abdullah S/O Javed Iqbal
(University of Gujrat)

Department:
Electrical

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 CHAPTER 1

INTRODUCTION

Service Industries Limited & PAK Fan

Service Industries Limited (SIL) and PAK F are public limited companies. Servis is Pakistan's
famous shoe brand and is the largest manufacturer of footwear, tyres & tubes for two-wheelers,
while PF is famous for fans, washing machine and air coolers. They are the largest exporter of
the country for the last many years. The Service has it's headquartered in Lahore and factories
in Gujrat and Muridke. The company employs more than 9,000 people in its facilities located
in Gujrat and Muridke and exports its products primarily to Germany, Italy, France and the
UK. The Pak Fan has it’s headquartered and factory in Gujrat. The company has more than
1000 employs and exports its products primarily to Saudi Arabia. With a strong emphasis on
product quality and innovation, both companies have built both domestic and international
recognition of the company’s products. The visionary leadership and hardworking
management team have led companies to some position in the business arena. Both industries
are today an efficient, progressive and customer-oriented organization. These companies are
also involved in many Social activities, they have been a regular contributor to community
welfare, charities, and causes. They have developed a wide range of consumer products, to
enhance business and accommodate the different segments of society.

History of Servis Industry:

The Servis was founded by Ch. Nazar Muhammad, Ch. Muhammad Hussain from Gujrat and
Muhammad Saeed from Gujranwala more than 50 years ago. In 1954, they installed a shoe
manufacturing plant at industrial area Gulberg, Lahore. This started production in the same
year. The industry started manufacturing various types of shoes. Later management shifted the
factory from Lahore to Gujrat. Service Sales Corporation (Pvt.) Ltd. the Group’s marketing
company was established in 1959. Today, the production side of the company has flourished
into Service Industries Limited (SIL) which has world-class shoes, tyres, tubes and rubber
production facilities in Gujrat and Muridke. SIL is also the leading exporter of footwear.
Service Sales Corporation (Pvt.) Ltd. (SSC) is today Pakistan’s leading footwear retailer.

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History PAK Fan Industry:
The history of PAK brand is as vibrant and brilliant as the products themselves. The company
traces its origins back to 1936 when Mr Abdul Wahid, the founder and the president of the
Company started its operations as the manufacturer of light engineering and utility products.
The setting up of this project is a pioneering achievement of Mr Abdul Wahid as the time when
there were no facilities, assistance or guidance in this part of the sub-continent. He simply took
it as a challenge, undeterred by the initial difficulties and sticks to his motto “No compromise
on Quality”. As a result of product innovation, exceptional quality and through distinct
marketing strategies, his determined efforts were soon crowned with success and Pak Fans
become the leading fan manufacturer in Pakistan.
1936: started its operation as the manufacturer of light engineering and utility products.
1945: Company for the first time embarked on the manufacturing of the Electric Fans before
the independence of Pakistan (1947).
1962: Company cemented its position among the top companies in Pakistan.
1970: Company extended its product range, introduced different models and then kept on
increasing the range over the years.
1981: A modern automatic Japanese Plant was installed to manufacture Enameled Copper
wires of top international quality and marketed under the brand name PAK SUPER.
1989: To live up to the progressive image the Company keeps itself abreast of the latest
technological developments around the world. And this enables the Company to continually
introduce ever new concepts in electric fans, the ‘remote controlled fans”.
1990: Towards its role as a responsible corporate citizen Wahid Industries keeps on
encouraging and contributing to social uplift programs. At Gujrat, it set up a modern hospital
– equipped with the latest facilities and top-notch medical personnel.
1992: Latest CNC machines and injection moulding machines were installed to make the
company more self-reliant in its production.
1993: Company diversified its operations and started manufacturing washing machine with
plastic as well as the metal body.
1997: Wahid Industries took off another project and started manufacturing driers and room air
coolers.
1999: in the year 1999-2000 Pak Fan achieved the highest international quality award ISO-
9002 certified company. Pak Fan also won the FPCCI Trophy 1999-2000.
2000: Company exported fans for the first time and marked its international presence.

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2001: Company won the highest export trophy award from that year, it is continuously
achieving this award.
2007: automated paint plant was installed to improve the finish of the product as well as reduce
environmental pollution.
As a result of its innovative excellence and ever-evolving technological process, PAK HOME
APPLIANCES remains the utmost choice – both at home and abroad.

Objectives of Internship

All the students of Bachelor of Science in Electrical Technology are required to spend 16
weeks of their last semester of study in any Organization, Institute or Firm for getting practical
experience and gain their Skill. I choose Service Industry Gujrat and Pak Fan for getting
practical exposure in order to set knowledge of these organizations for the internship. To work
practically in these organizations and correlate my classroom knowledge with reality to acquire
practical experience for my future career.
My objectives of doing an internship are:
 To gather the relevant information to compile and to develop skills and techniques that
directly applicable to my career. Check how bookish knowledge is implemented.
 To learn the practical activities in Different department in practical working areas.
 To gain practical experience and knowledge.
The purpose of this report is to describe my experience at SIL & PF and the knowledge that I
gained at these prestigious organizations.
I worked at Electrical Department to observe how the electrical system of the industries work
and to get familiar with its different sections.

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 CHAPTER 2

Electrical Department

To maintain the operations of the industry, every industry needs a maintenance

department. Where different kinds of problems in the industries are solved. SIL

and PF also have such department which is called Engineering department. It has

some sub-departments like Electrical, Mechanical, Welding and Woodwork.

As being a student of BS. Electrical Engineering, my working department was

the electrical department. Where different kinds of problems are solved, and tasks

are performed, like repair and maintenance of 1-phase & 3-phase motors up to

100KW, Installation and maintenance of electric switchboards, lights, machines,

LT panels, substations, wiring etc.

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2.1 Components
An industrial panel contains power and controlling circuit along with some
measurement and pilot devices.

Digital Meters
Digital Meters are door mounted digital display that allows an operator to monitor
analog process variables Level, Pressure, Temperature, etc.

Circuit Breaker
A circuit breaker is an automatically-operated electrical switch designed to
protect an electrical circuit from damage caused by overload or short circuit.

MCB (Miniature Circuit Breakers)

MCB is a protecting device. It is used before the feeder. This should be selected
according to the capacity of the feeder. MCB is rated under 100 amps. MCB trip
characteristics may not be adjustable. MCB is suitable for the low current circuit.

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MCCB (Moulded Case Circuit Breaker)

In most of the cases, the MCCB used as an incomer for higher capacity feeders
for better protection. MCCB is rated current in the range of 10-2500 amps.
Thermal operated for overload and magnetic operation for instant operation.
Moulded case circuit breakers are a type of electrical protection device that is
commonly used when load currents exceed the capabilities of miniature circuit
breakers. They are also used in applications of any current rating that require
adjustable trip settings, which are not available in plug-in circuit breakers
and MCBs.

CT/PT (Current and potential transformer)

These are also called instrument transformer. These are used to measure voltage
and current of different high voltage lines. CT is a type of instrument transformer
CT is used extensively for measuring current and monitoring the operation.
Current or voltage instrument transformers are necessary for isolating the
protection, control and measurement equipment from the high voltages of a
power system, and for supplying the equipment with the appropriate values of
current and voltage, generally these are 1A or 5Α for the current coils, and 220 V
for the voltage.

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Relays

Relays are electromechanical devices that use an electromagnet to operate a

couple of flexible contacts from an open situation to a closed station. The
advantage of relays is that it takes a comparatively small quantity of power to
work the relay coil. The electromechanical relay is an arrangement which comes
in a host of characters, sizes and designs and has many uses and applications in
electronic circuits. But while electrical relays can be used to allow low power
electronic or Auto type circuits to switch relatively high currents or voltages both
“ON” and “OFF”, some form of relay shift circuit is compulsory to switch it.

Over load relay

Over load relay is for the protection of motor from the over load. It senses the
load current and trips if it exceeds the limit. The Current limit has to be set
manually. It should be 80% of the full load current.

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CONTACTOR

Contactor is an essential component in the control panel. It actuates when the

signal from the controller (PLC, Relay logic) comes. It is similar to relay. It is
costlier than relay. It is used for a higher load.

3.1 Motor Starters

Different starting methods are employed for starting induction motors because
Induction Motor draws more starting current during starting. To prevent damage
to the windings due to the high starting current flow, we employ different types
of starters.

 Direct Online Starter (DOL) / Motor starter

The simplest form of motor starter for the induction motor is the Direct On Line
starter. The Direct On Line Motor Starter (DOL) consist of an MCCB or Circuit
Breaker, Contactor and an overload relay for protection. Electromagnetic
contactor which can be opened by the thermal overload relay under fault
conditions.
Typically, the contactor will be controlled by separate start and stop buttons, and
an auxiliary contact on the contactor is used, across the start button, as to hold in
contact. I.e. the contactor is electrically latched closed while the motor is
operating.

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Principle of Direct On Line Starter (DOL):

The main heart of DOL starter is Relay Coil. Normally it gets one phase constant
from incoming supply Voltage (A1). when Coil gets second Phase relay coil
energizes and Magnet of Contactor produce electromagnetic field and due to this
Plunger of Contactor will move and Main Contactor of starter will close and
Auxiliary will change its position NO become NC and NC become. When We
Push the start Button Relay Coil will get the second phase from Supply Phase-
Main contactor (5)-Auxiliary Contact (53)-Start button-Stop button-96-95-To
Relay Coil (A2). Now Coil energizes and Magnetic field produce by Magnet and
Plunger of Contactor move. The main Contactor closes and Motor gets supply at
the same time Auxiliary contact become (53-54) from NO to NC. Relay coil gets
supply even though we release the Start button. When We release Start Push
Button Relay Coil gets Supply phase from Main contactor (5)-Auxiliary contactor
(53) – Auxiliary contactor (54)-Stop Button-96-95-Relay coil.
In Overload Condition of Motor will be stopped by intermission of Control circuit
at Point 96-95. When we push Stop Button Control circuit of Starter will be a
break at stop button and Supply of Relay coil is broken, Plunger moves and close
contact of Main Contactor becomes Open, Supply of Motor is disconnected.

Circuit diagram:

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  Star – Delta Starter

Most induction motors are started directly on line, but when very large motors
are started that way, they cause a disturbance of voltage on the supply lines due
to large starting current surges. To limit the starting current surge, large
induction motors are started at reduced voltage and then have full supply voltage
reconnected when they run up to near rotated speed.

Working Principle of Star-Delta Starter

This is the reduced voltage starting method. Voltage reduction during star-delta
starting is achieved by physically reconfiguring the motor windings as illustrated
in the figure below. During starting the motor windings are connected in star
configuration and this reduces the voltage across each winding 3. This also
reduces the torque by a factor of three. After a period, the winding is reconfigured
as delta and the motor runs normally. Star/Delta starters are probably the most
common reduced voltage starters. They are used to reduce the start current
applied to the motor during start as a means of reducing the disturbances and
interference on the electrical supply.
The Star/Delta starter is manufactured from three contactors, a timer and a
thermal overload. The contactors are smaller than the single contactor used in a
Direct-on-Line starter as they are controlling winding currents only. The currents
through the winding are 1/root 3 (58%) of the current in the line. There are two
contactors that are close during run, often referred to as the main contractor and
the delta contactor. These are AC3 rated at 58% of the current rating of the motor.
The third contactor is the star contactor and that only carries star current while
the motor is connected in star. The current in star is one third of the current in
delta, so this contactor can be AC3 rated at one third (33%) of the motor rating.

Star-delta Starter Consists following units

 Contactors (Main, star and delta contactors) 3 No’s (For Open State
Starter) or 4 No’s (Close Transient Starter).
 Time relay (pull-in delayed) 1 No.
 Three-pole thermal overcurrent release 1 No.

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Circuit diagram:

 Forward / Reverse motor control

The forward reverse motor control is used in a system where forward and
backward or upward and downward movement in the operation are needed.

Working:

The clockwise (forward) and counterclockwise (reverse) rotation of a motor can

be caused by interchanging the connection of any of the two of its three terminals.
Figures below will show how this can be done.
Contractors F and R are interlocked. It means that if the contacts (1-2, 3-4, 5-6)
of contractor R cannot be closed. On the other hand, if the contacts (1-2, 3-4, 5-
6) of contractor R are closed, contacts (1-2, 3-4, 5-6) of contractor F cannot be
closed. Note that when the contacts of contractor F are closed, L1 is connected to
T1 through contact F (1-2), L2 is connected to T2 through contact F (3-4), and
L3 is connected to T3 through contact R(5-6).The motor M will run forward.

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When the contacts of contractor R in the Figure (a) are closed, L1 is connected to
T3 through contact R (1-2), L2 is connected to T2 through contact R (3-4) and L3
is connected to T1 through contact R (5-6). The motor M will run reverse.
Referring to the control circuit on Figure (a), pressing the forward push button F
will energize contactor F. Maintaining contact F (13 14) will close to maintain
contact or F continually energized even if the forward push button is release.
Contactor F (11-12) will open to prevent contactor R to be energized. Contacts F
(1-2, 3-4, 5-6) will close to run motor M on forward direction. Pressing the stop
push button will de-energized contactor F. This will cause the contacts R(1-2, 3-
4, 5-6) to open and stops the motor M from running forward. Contacts F(11-12)
will close again. Maintaining contact F(13-14) will open.
Pressing the reverse push button R will energize contactor R. Maintaining contact
R(13-14) will close to maintain contactor R continually energize evenif the
reverse push R button is release. Contacts R(11-12) will open to prevent contactor
F to be energized. Contacts R (1-2, 3-4, 5-6) will close to run motor M on reverse
direction. Pressing the stop push button again will de-energized contactor R. This
will cause the contacts R(1-2, 3-4, 5-6) to open and stops the motor from running
reverse. Contact R(11-12) will close again. Maintaining contact R(13-14) will
open.

Power circuit:

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Control Circuit:

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 CONCLUSION

I found a very good practical learning environment at Service industries Limited

Gujrat. The Management of Service Industry Limited is very cooperative. They
assigned me task and keep me busy in learning different things. They provide
guidance and support in difficulties.
On the whole, this internship was a useful experience. I have gained new
knowledge and skills. I achieved several of my learning goals. Students must
complete the courses related to their internship before beginning the program.
Completing the related courses before the internship helps the students to
understand the topic better.

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