INTERNSHIP REPORT

on

(Schneider Electric Pakistan)

Shiraz Ahmed Khan

Electrical Engineering Department

E-mail: shiraz_sherwani@yahoo.com

Mob: 0345-3958029

Duration Of Period: 17th Dec 2014 to 7th

Jan2015

TABLE OF CONTENTS

Acknowledgment………………………………………………………………………….03

Preface……………………………………………………………………………………..04

Overview of the organization……………………………………………………………...05

Organizational structure…………………………………………………………………...08

Training program………………………………………………………………………….10

Conclusion ………………………………………………………………………………..17

ACKNOWLEDGMENT:

First of all I want to thanks The Almighty Allah, who gave me this great opportunity to be a part

of such a great Multinational Company as an internee and made me enable to learn a lot of

practical knowledge.

The successful compilation of this internship and report was possible due to help and support of

various people, who were there for me whenever I needed them. This includes first of all the

company, Schneider Electric itself, which gave me the opportunity to spend time in its highly

professional environment and gave me all the opportunities to learn.

I would like to thank Mr. Salman Hakkani and Ms. Nida Javed, Human Resource Department,

Mr. Farhan Rajput Inspection and Testing Department for giving a lot of knowledge as a Testing

Engineer, Mr. Saqib Design Engineering Department for their kind support and guidance, Mr.

Omair Sheikh and Ms. Shana Production Depart, I am also thankful to Mr. Saad Ahmad Zia

Head of Final Inspection and Testing Department along with the whole staff for giving me an

opportunity to learn and gain hand-on experience in the factory. Whole technical department has

been very supportive during my internship. It will surely be a lifetime remembrance for me and I

feel privileged working with such committed and elegant engineers and staff. I would also like to

thank all the workers who had cooperated a lot throughout my internship.

Shiraz Ahmed Khan

PREFACE

Internship is the intermediate step of an engineering student's academic career. For a student of

the Department of Electrical Engineering, training is essential for the complete understanding of

the concepts learned from formal education. There remains a huge gap between academic

learning and the implementation of that hypothetical knowledge in the practical world of modern

Engineering. Internship can compensate this wide gap as it brings opportunities for a student to

comprehend the main trends of engineering activities.

In compiling this report I have intended to provide a synthesis of theoretical approaches and

methods of implementing them in the world of engineering. I have tried to discover the relationship

between theoretical and practical type of knowledge. I have tried to bridge the gap between

theoretical assumptions and practical necessities. During the entire course of our academic study

we remain engaged in theoretical learning where the primary objective is academic success. A

concise knowledge of the modern engineering arena can only be attained through the pragmatic

implementation of hypothetical ideas, which we learn from our academic activities.

With these objectives, I have made all possible efforts and the necessary investigations to submit

this paper in an enlightened form in a very short time. I have tried my level best to eliminate errors

from the paper. As I had to complete my internship within a short period of time so the study

admits its limitations.

I visited the Schneider Electric as a part of the internship program starting from 17 December

2014 to 07 January 2015.

Overview of the organization

Health, Safety & Environment

For Schneider Electric Private(LTD),Karachi Pakistan. Health, Safety & Environment possess

utmost significance. The company ensures that:

manner acceptable to the local communities.

deliberate harm, damage or loss.

To make sure that these guidelines are followed, the company provides Safety, Security, Health

& Environment training and information to all employees, contractors and others who work with

Schneider Electric or handle their products.

Schneider Electric’s Brief History

Schneider Electric SE is a European multinational corporation that specializes in electricity

distribution, automation management and produces installation components for energy

management. It is headquartered in Rueil-Malmaison, France and is also based at the World

Trade Center of Grenoble.

As a global specialist in energy management with operations in more than 100 countries,

Schneider Electric offers integrated solutions across multiple market segments, including

leadership positions in energy and infrastructure, industrial processes, building automation, and

data centers/networks, as well as a broad presence in residential applications. Focused on making

energy safe, reliable, and efficient, the company's 100,000+ employees achieved sales of more

than 15.8 billion euros in 2009, through an active commitment to help individuals and

organizations “Make the most of their energy”.

Products: 1. Access to Energy Collective Solutions 2. Access to Energy Home Systems

3. Audio-Video Solutions

4. Boxes, Cabling & Interfaces

5. Building Management System

6. Busway & Cable Management

7. Contactors & Protection Relays

8. Cooling Solutions

9. Cyber security Solutions

10. Data Centers and Server Rooms and Network Closets

11. Din rail modular devices

12. Distribution and communication systems

13. Emergency Lighting

14. Energy Management Services

15. EVlink charging solutions for electric vehicles

16. Feeder Automation

17. Fuse Switches

18. HMI (terminals and industrial PC)

19. Home Control

20. IED User Software

21. Industrial & Specialized UPS and Power Conversion

22. Industrial communication

23. Industrial plugs and sockets

24. Installation material

25. Insulation monitors

26. Interface, Measurement & Control Relays

27. IT Power Distribution

28. IT Racks and Accessories

29. IT Services

30. Motion & Drives

31. Motor Starters

32. MV Circuit Breakers & MV Contactors

33. MV Disconnectors, Switches, Switch-Disconnections, Reclosers

34. MV Instrument Transformer

35. MV Switchgear

36. MV Transformers

37. MV/LV Prefabricated Substations

38. Network Connectivity

39. Network Management Software

40. PAC, PLC & other Controllers

41. Panel boards & Switchboards

42. Power & Energy Monitoring System

43. Power Circuit breakers & Switches

44. Power Quality

45. Power supplies & transformers

46. Protection Relays by Application

47. Protection Relays by Range

48. Pushbuttons, Switches, Pilot Lights, Control stations & Joysticks

49. Security and Environmental

50. Sensors & RFID system

51. Signaling Units

52. Software

53. Solar for Ground Mounted Plants

54. Solar for Industrial & Commercial Rooftops

55. Solar for Residential

56. Solar Off-Grid and Back-up

57. StruxureWare for Data Centers

58. Surge Protection and Power Conditioning

59. Systems and architectures

60. Telemetry & Remote SCADA Systems

61. Telemetry System

62. Uninterruptible Power Supply (UPS)

63. Universal Enclosures

64. Weather Observation Hardware

These are the main products of Schneider Electric ,globally. These are further divided into too

many sub classes.

ORGANIZATIONAL STRUCTURE:

PROCESS WORKFLOW:

The process workflow in Schneider Electric starts from the meeting of client with the member of

Sales department agreeing on a particular order including numerous items. The department P1

i.e. of Instruction and Planning took over the order and is responsible throughout the completion

of the project. Meanwhile a Project Manager is assigned who act as a person to whom the client

will be discussing the needs and objective of the project. The Project Manager guides the client

with its available design of the project and making necessary changes in it. Once the design is

approved by the client, instruction come from Planning department to fetch Pre-fab plans, Job

cards and MPS (Material Preparation System). The workflow continues with the job study and

internal planning of P31 i.e. Fabrication department which includes drawing study as given by

the Design department , Job card verification and PDF formation. Internal verification is carried

out which include article verification, machine utilization, meeting desired targets and accessing

all raw material required.

With these target achieved, the material begin to be prepared which include raw materials such

as sheet, copper and paint. The making of these materials run through the process of punching,

bending, welding and paint, finally setting a prerequisite need of the completion of the project.

Once the design is fabricated by the Fabrication department, the work of P6 i.e. Drawing office

starts with the implementation of design as approved by client and making necessary changes in

it. The Single line diagram (SLD) is drawn by the designer on a software E3 and all possible

views of the project is implemented on AUTOCAD software. The designer provides the design

to the Production department ready to implement the design.

Production department is responsible for carrying out the production and assembling of the parts

required in the project. The workers according to the instruction implement the design and

assemble the parts required, the wireman implement wiring according to SLD and finally the

project is forwarded to the WIP inspector to investigate the design. The final inspection is

carried out by Testing and Inspection department which include Quality persons keeping a check

in balance of the quality of the material used.

The project then is handed over to Logistics and kitting is done before delivering to the

transporter for the final delivery.

Hence, from the placement of order of client to the delivery of the order, the Project Manager is

responsible for completion of the project well on time. Moreover he/she act as a person who

fulfill all the needs and changes made by the client during the project and informing them to all

the department engaged in the project in the company.

ORGANIZATIONAL HIERARCHY CHART:

TRAINING PROGRAM:

The training program at Schneider starts with the Fabrication department where Mr. Babar took

over my supervision. He surveyed the process of fabrication to me which runs throughout the

company. The fabrication of the electrical equipment includes:

a) PUNCHING MACHINE:

The metal sheet remained same for LV as well as for MV. These sheets are brought into

the CNC (Computerized Numeric Control) machine where the programmer through

programming made the outfit, punches and holes in the metal sheet.

b) TAG IDENTIFICATION PART:

Once the punches and holes are made into the sheet, tags are put up so as to identify

which part is used to specify which part.

c) BENDING:

Bending of the sheet is done manually. It has lot of variation. Its basic purpose is to give

particular angle to the shape.

d) WELDING:

Welding is done on the sheet wherever necessary and the shape is ready to be painted.

e) GALVANIZING:

There are some part in the design which are actually moving parts and because of their

motion , the paint may be flaked off. So in order to avoid that, galvanizing is done on the

moving part, this reduces the wear and tear of the design.

f) PAINT:

Painting are of two types:

Wet paint

Powder paint

Wet paint takes more time to dry as compared to powder paint. Here in Schneider Electric,

powder paint is mostly done on stationary part which runs through following processes:

i. PRE-CLEANING:

The design is cleaned before it is being painted with Zinc Phosphate ZnP

to clean oily surface and to increase the adhesive property for painting.

Zinc Phosphate is sprayed by high pressure nozzle so as to avoid rusting

during transportation.

ii. DRYING:

Once the design is pre-cleaned by Zinc Phosphate it is dried by blowing

air onto it.

iii. POWDERING:

Powdering is done by using powder gun on the design. Powder impact are

of two types, one which have textures which is mainly used for rough

surface and the other one do not have textures which is used for plain

surface. The powder paint having textures is better and recommendable

for better paint.

iv. OVEN/MELTING OF POWDER:

Normally the powder sprayed on the design is melted at 180oC in an oven

which was actually designed to run on 200oC. The purpose of melting is to

have proper paint surface.

In the Production department, I was accompanied by Mr. Umair and Mr. Ahsen, who gave

information about electrical equipment which are being used in the industry whose description

are as follows:

ELECTRICAL SWITCH GEAR:

Electrical switchgear is a generic term which includes all the switching devices associated with

mainly power system protection. It also includes all devices associated with control, metering

and regulating of electrical power system. Assembly of such devices in a logical manner forms

switchgear.

A switch gear has to perform the function of carrying, making and breaking the normal load

current like a switch and it has to perform the function of clearing the fault in addition to that it

also has provision of metering and regulating the various parameters of electrical system. Thus

the switchgear includes circuit breaker, transformer, protection relay, measuring instrument,

electrical switch, miniature circuit breaker, lightening arrestor or surge arrestor, electrical

isolator and other associated equipment.

MV SWITCHGEAR PANEL TYPES:

Schneider Pakistan manufactures panels related to Medium Voltage (MV) in Pakistan.The main

task of medium-voltage switchgear is cost-efficient and safe power distribution. Schneider's

Medium Voltage Switchgear provides centralized control and protection of medium-

voltage power equipment and circuits in industrial, commercial, and utility installations

involving generators, motors, feeder circuits, and transmission and distribution lines.

Schneider Pakistan produces many types of MV Panels, but most common and wanted products

of Schneider are listed below:

PIX

RK

WKK8

RK type MV panels are mainly used by WAPDA in which the vacuum circuit breaker usually

comes out with the door. On the contrary WKK8 is a standard product for K-Electric in which

the trolley of vacuum circuit breaker come out after opening the door. PIX is commercially

offered by Schneider for local use having microcontroller based programming

CIRCUIT BREAKERS:

Electrical circuit breaker is a switching device which can be operated manually as well as

automatically for controlling and protection of electrical power system respectively. It mainly

consists of fixed contacts and moving contacts. In normal “on” condition of circuit breaker, these

two contacts are physically connected to each other due to applied mechanical pressure on the

moving contacts. There is an arrangement stored potential energy in the operating mechanism of

circuit breaker which is realized if switching signal given to the breaker. The potential energy

can be stored in the circuit breaker by different ways like by deforming metal spring, by

compressed air, or by hydraulic pressure. But whatever the source of potential energy, it must be

released during operation. Release of potential energy makes sliding of the moving contact at

extremely fast manner. All circuit breaker have operating coils (tripping coils and close coil),

whenever these coils are energized by switching pulse, the plunger inside them displaced. This

operating coil plunger is typically attached to the operating mechanism of circuit breaker, as a

result the mechanically stored potential energy in the breaker mechanism is released in forms of

kinetic energy, which makes the moving contact to move as these moving contacts mechanically

attached through a gear lever arrangement with the operating mechanism. After a cycle

of operation of circuit breaker the total stored energy is released and hence the potential energy

again stored in the operating mechanism of circuit breaker by means of spring charging motor or

air compressor or by any other means. Moreover the circuit breaker has to carry large rated or

fault power. Due to this large power there is always dangerously high arcing between moving

contacts and fixed contact during operation of circuit breaker. The arc in circuit breaker can be

quenching safely if the dielectric strength between the current carrying contacts of circuit

breaker increases rapidly during every current zero crossing of the alternating current. The

dielectric strength of the media in between contacts can be increased in numbers of ways, like by

compressing the ionized arcing media since compressing accelerates the deionization process of

the media, by cooling the arcing media since cooling increase the resistance of arcing path or by

replacing the ionized arcing media by fresh gasses. Hence a numbers of arc quenching processes

should be involved in operation of circuit breaker.

o TYPES OF CIRCUIT BREAKERS:

According to their arc quenching media the circuit breaker can be divided as-

Oil circuit breaker.

Air circuit breaker.

SF6 circuit breaker.

Vacuum circuit breaker.

OIL CIRCUIT BREAKER:

Mineral oil has better insulating property than air. In oil circuit breaker the fixed contact and

moving contact are immerged inside the insulating oil. Whenever there is a separation

of current carrying contacts in the oil, the arc in circuit breaker is initialized at the moment of

separation of contacts, and due to this arc the oil is vaporized and decomposed in mostly

hydrogen gas and ultimately creates a hydrogen bubble around the arc. This highly compressed

gas bubble around the arc prevents re-striking of the arc after current reaches zero crossing of the

cycle. The oil circuit breaker is the one of the oldest type of circuit breakers.

AIR CIRCUIT BREAKER:

This type of circuit breakers, is those kind of circuit breaker which operates in air at atmospheric

pressure. After development of oil circuit breaker, the medium voltage air circuit breaker (ACB)

is replaced completely by oil circuit breaker in different countries. But in countries like France

and Italy, ACBs are still preferable choice up to voltage 15 KV. It is also good choice to avoid

the risk of oil fire, in case of oil circuit breaker. In America ACBs were exclusively used for the

system up to 15 KV until the development of new vacuum and SF6 circuit breakers.

SF6 CIRCUIT BREAKERS:

A circuit breaker in which the current carrying contacts operate in sulphur hexafluoride or

SF6 gas is known as an SF6 circuit breaker. SF6 has excellent insulating property. SF6 has high

electro-negativity. That means it has high affinity of absorbing free electron. Whenever a free

electron collides with the SF6 gas molecule, it is absorbed by that gas molecule and forms a

negative ion. These negative ions obviously much heavier than a free electron and therefore over

all mobility of the charged particle in the SF6 gas is much less as compared other common gases.

Hence, for heavier and less mobile charged particles in SF6 gas, it acquires very high dielectric

strength. Not only the gas has a good dielectric strength but also it has the unique property of fast

recombination after the source energizing the spark is removed. The gas has also very good heat

transfer property. Due to its low gaseous viscosity (because of less molecular

mobility) SF6 gas can efficiently transfer heat by convection. So due to its high dielectric

strength and high cooling effect SF6gas is approximately 100 times more effective arc quenching

media than air. Due to these unique properties of this gas SF6 circuit breaker is used in complete

range of medium voltage and high voltage electrical power system. These circuit breakers are

available for the voltage ranges from 33KV to 800KV and even more.

VACUUM CIRCUIT BREAKERS:

A vacuum circuit breaker is such kind of circuit breaker where the arc quenching takes place in

vacuum. The technology is suitable for mainly medium voltage application. The operation of

opening and closing of current carrying contacts and associated arc interruption take place in a

vacuum chamber in the breaker which is called vacuum interrupter. The vacuum interrupter

consists of a steel arc chamber in the centre symmetrically arranged ceramic insulators. The

vacuum pressure inside a vacuum interrupter is normally maintained at 10 – 6

bar. The material

used for current carrying contacts plays an important role in the performance of the vacuum

circuit breaker. CuCr is the most ideal material to make VCB contacts.

The main aim of any circuit breaker is to quench arc during current zero crossing, by establishing

high dielectric strength in between the contacts so that reestablishment of arc after current zero

becomes impossible. The dielectric strength of vacuum is eight times greater than that of air and

four times greater than that of SF6 gas. This high dielectric strength makes it possible to quench

a vacuum arc within very small contact gap. For short contact gap, low contact mass and no

compression of medium the drive energy required in vacuum circuit breaker is minimum. When

two face to face contact areas are just being separated to each other, they do not be separated

instantly, contact area on the contact face is being reduced and ultimately comes to a point and

then they are finally de-touched. Although this happens in a fraction of micro second but it is the

fact. At this instant of de-touching of contacts in a vacuum, the current through the contacts

concentrated on that last contact point on the contact surface and makes a hot spot. As it is

vacuum, the metal on the contact surface is easily vaporized due to that hot spot and create a

conducting media for arc path. Then the arc will be initiated and continued until the

next current zero. At current zero this vacuum arc is extinguished and the conducting metal

vapor is re-condensed on the contact surface. At this point, the contacts are already separated

hence there is no question of re-vaporization of contact surface, for next cycle of current. That

means, the arc cannot be reestablished again. In this way vacuum circuit breaker prevents the

reestablishment of arc by producing high dielectric strength in the contact gap after current zero.

POTENTIAL TRANSFORMER:

Potential transformer or voltage transformer gets used in electrical power system for stepping

down the system voltage to a safe value which can be fed to low ratings meters and

relays. A voltage transformer theory or potential transformer theory is just like a theory of

general purpose step down transformer. Primary of this transformer is connected across the phase

and ground. Just like the transformer used for stepping down purpose, potential transformer i.e.

PT has lower turns winding at its secondary. The system voltageis applied across the terminals of

primary winding of that transformer, and then proportionate secondary voltage appears across

the secondary terminals of the PT.

CURRENT TRANSFORMER:

A current transformer (CT) is used for measurement of alternating electric currents. Current

transformers, together with voltage (or potential) transformers (VT or PT), are known as

instrument transformers. When current in a circuit is too high to apply directly to measuring

instruments, a current transformer produces a reduced current accurately proportional to the

current in the circuit, which can be conveniently connected to measuring and recording

instruments. A current transformer isolates the measuring instruments from what may be very

high voltage in the monitored circuit. Current transformers are commonly used in metering

and protective relays in the electrical power industry.

PROTECTIVE RELAY :

A relay is automatic device which senses an abnormal condition of electrical circuit and closes

its contacts. These contacts in turns close and complete the circuit breaker trip coil circuit hence

make the circuit breaker tripped for disconnecting the faulty portion of the electrical circuit from

rest of the healthy circuit.

MINIATURE CIRCUIT BREAKER (MCB):

Nowadays we use more commonly miniature circuit breaker or MCB in low voltage electrical

network instead of fuse.

The MCB has some advantages compared to fuse.

1. It automatically switches off the electrical circuit during abnormal condition of the network

means in over load condition as well as faulty condition. The fuse does not sense but miniature

circuit breaker does it in more reliable way. MCB is much more sensitive to over current than

fuse.

2. Another advantage is, as the switch operating knob comes at its off position during tripping,

the faulty zone of the electrical circuit can easily be identified. But in case of fuse, fuse wire

should be checked by opening fuse grip or cutout from fuse base, for confirming the blow of fuse

wire.

3. Quick restoration of supply cannot be possible in case of fuse as because fuses have to be

rewirable or replaced for restoring the supply. But in the case of MCB, quick restoration is

possible by just switching on operation.

4. Handling MCB is more electrically safe than fuse.

Because of to many advantages of MCB over fuse units, in modern low voltage electrical

network, miniature circuit breaker is mostly used instead of backdated fuse unit.

SURGE ARRESTOR:

A surge arrester is a device to protect electrical equipment from over-voltage transients caused

by external (lightning) or internal (switching) events. Also called a surge protection device

(SPD) or transient voltage surge suppressor (TVSS), this class of device is used to protect

equipment in power transmission and distribution systems.

ELECTRICAL ISOLATORS/ EARTHING SWITCH IN SWITCH GEAR:

Circuit breaker always trip the circuit but open contacts of breaker cannot be visible physically

from outside of the breaker and that is why it is recommended not to touch any electrical circuit

just by switching off the circuit breaker. So for better safety there must be some arrangement so

that one can see open condition of the section of the circuit before touching it. Isolator is a

mechanical switch which isolates a part of circuit from system as when required. Electrical

isolators separate a part of the system from rest for safe maintenance works.

DISTRIBUTION BOARDS:

A distribution board (also known as panel board or breaker panel) is a component of

an electricity supply system which divides an electrical power feed into subsidiary circuits, while

providing a protective fuse or circuit breaker for each circuit, in a common enclosure. Normally,

a main switch, and in recent boards, one or more residual-current devices (RCD) or residual

current breakers with overcurrent protection (RCBO), are also incorporated.

o TYPES OF DISTRIBUTION BOARD:

Light distribution board

Emergency distribution board

UPS distribution board

VARIABLE FREQUENCY DRIVES (VFD):

VFD is a power electronics based device which converts a basic fixed frequency,

fixed voltage sine wave power (line power) to a variable frequency, variable output voltage used

to control speed of induction motor(s). It regulates the speed of a three phase induction motor by

controlling the frequency and voltage of the power supplied to the motor.

:

CONCLUSION:

The organization provided interesting insight of how electrical equipment are assembled, tested

and forwarded to client. Simultaneously, it was a good opportunity to put in practice the

theoretical concepts learned during the academic year. Last but not least, it was a great

opportunity for developing personal intellectual skills, management skills and self-motivation to

work with a skillful and a hardworking team.