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Group Members:
 Muhammad Waqar
 Muhammad Munir
 Noraiz khan
 Muhammad Amir Salem
 Hasan Iqbal Baig

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Table of Contents:
Contents
Abstract:....................................................................................................................................... 3
Introduction: ................................................................................................................................. 3
Background theory:........................................................................................................................ 3
Procedure: .................................................................................................................................... 4
Press-Shop Department: ............................................................................................................. 4
Terminal Block Assembly: ............................................................................................................ 6
SMT Department:.................................................................................................................... 8
Final Assembly: .......................................................................................................................... 8
Testing & Calibration: ................................................................................................................. 9
SPDP Department:...................................................................................................................... 9
Conclusion: ................................................................................................................................... 9

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Abstract:
This report deals with the working of the Energy meter production flow. It covers the static system
manufacturing and the steps followed by it. The report indicates each and every step in a very descriptive
manner and also indicates the safety measures taken during the process.
Introduction:
In the past, the world had known only eight wonders but within few centuries, science has created like
hundreds of them. Science has conquered the skies, lit the dark nights and explore the distant places.
Electricity is one of revolutionary measures out of many. Edison and its company was the first to facilitate
this wonder with the common people. They built their first electrical system and hence meters were
designed to keep track of the energy usage. Thus electric meters also have a history from electrolytic
meters, pendulum meters, motor meters to the digital meters. Even though the smart meters have also been
in the market to facilitate the producer and consumer.
In this report, we are discussing the manufacturing of the electric meter. EMP department in PEL deals
with the production of digital meter. EMP stands for energy meter production department. EMP
department started the production of static meter in 2005 and currently 4692 workers are working in it.
The flow is discussed in it along with the safety measures that are taken during the process is discussed in
this report.
Background theory:
In the background theory, we are discussing what is three phase supply along with the inductive and
capacitive load along with current transformer and potential transformer? Moreover we will also discuss
what is power factor along with varistor and EPROM?
First of all, we have three phase supply which is defined as a common method of AC electric power
generation, transmission and distribution. It is most commonly used polyphaser system which is been used
in electrical grids to transfer power in whole world for years. Moreover, with the help of it, the heavy loads
along with large power motors are driven. The inductive loads are defined as resist changes in current and
as such when we measure current and it lags the voltage with 90 degrees and is measured in Henrys. One
big application of it is electromagnetic field in which motors, solenoids and relays are inductive in nature.
Unlike inductive load, in capacitive load the current wave leads the voltage by 90 degrees rather than
lagging. Camera flash is the example of capacitive load. Moving to CT, CT is current transformer that
produces an alternating current in its secondary side which is proportional to the alternating current in the
primary side. On the other side, voltage transformers are also called potential transformers which is
connected in parallel with instrument transformer. It is designed in a way that negligible load is present to
the supply and has an accurate voltage to phase ratio to enable precise secondary connected metering. The
ratio of the actual electrical power dissipated by an AC circuit to the product of the RMS values of current
and voltage. The difference between the two is caused by the reactance in the circuit and represents the

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power that doesn’t do useful work. VARAISTOR is an electric component having an electrical resistance
which varies with the applied voltage. It is also known as the voltage dependent resistor which has a non-
linear, non-ohmic current and voltage characteristics which is similar to the working of the diode. EPROM
is the programmable memory device which can be erased and then can be reused. Generally erasure is
done with the help of UV radiation through the window that is designed into the memory chip.
Procedure:
The production of the digital meter is divided into following processes:
 Press-Shop
 Terminal block assembly
 SMT department
 Final Assembly
 Testing & Calibration
 SPDP Department
 Safety Instructions
Press-Shop Department:
First of all, the process which triggers the digital meter production is called “Rod Cutting”. In this
department, the rod which is in raw form is cut down into small pieces. The pieces length is generally
kept up to 136mm. The diameter is generally 7mm according to our requirement. The next process is
called “Bending” in which rod is bent into U shaped with high temperature and pressure. The neutral
looks like this:
Figure 1: U-Shaped Neutral
The next step is called “knurling” in which impressions are added on the neutral. It is usually done so that
to increase the grip of meter wire with the screw.
Hasan Baig [Date] [Course title]

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The next step is called the “Drilling” in which holes aremade for the Earthwire. Generally the holes arekept
of 3.3m size.
Figure 3: Drilling
After the drilling process, we move to the “Punching” where we make a hole on the bottom of U shaped
Neutral. This is generally done for fitting the base with the screw.
Figure 4: Punching
Then comes the process of “Re-drilling” which is done for the safety and for the cost effectiveness. In
re-drilling the diameter is kept at 3.5mm. After re-drilling, the “Threading” is done for screw placement.
Generally after threading, holes are very sharp which can fade the finger prints. So in order to avoid
that, the counter drilling is done to remove the sharpness the “burs”. This process is known as “burs
removal process”. The exact same process is followed for the pressure plates as well. The pressure
plates also have the impressions and also undergoes the drilling and threading process. In three phase
system, there are six pressure plates and one neutral of U shaped. The pressure plates looks like this:
Figure 2 Knurled U shaped Neutral

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Figure 5: Pressure Plates
Terminal Block Assembly:
For the terminal block assembly, the prerequisites are U shaped Neutral and six pressure plates for the 3
phase system. The terminal block assembly is also called “shunt assembly” which consists of black
harness and pressure plates. The shunt for three phase consists of two main parts which are“Casket”
and “Bakelite material”. The Bakelite material is used to avoid dust from entering into block. It is pasted
with the help of glue to the block and is imported from the market. Casket is block possessing the
pressure plates along with the neutral. Both the neutral and pressure plates arefixed with the help of
screws. They are then attached with the wires which are made in the same department, there is insulator
between the casket and Bakelite materialto avoid sparking. Moreover it can withstand the 100 amp
current which can destroy the circuit. It will blow itself but save the circuit. The shunt for three phase is
as follows:

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Figure 6 3-phase Shunt
Similarly, for one phase shunt device, a paint picture is attached as below:
Figure 7 1-phase Shunt
Only two pressure plates areshown it although there are four in the single phase and six pressure plates
in three phase. So this shunt is then attached with the SMT board and then sent to final assembly for
testing. There is another sub department in the terminal block assembly department which is named as
“Current transformer & Potential Transformer”. The wires are generally formed in this department with
pressure plates attached on them. These wires are then attached with the CT/ PT, which is then further
attached with the shunt of terminal block. The CT/ PT is used in the static transformer to prevent energy
from the theft. It wasn’t present in the electromagnetic induction meters but in static part, it is present.
The meter will still work if someone cut the neutral wire and temper the meter.

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SMT Department:
SMT stands for Surface mounted technology. It is four layer PCB possessing the combination of capacitor,
resistor, regulator and EEPROM. The wave of 220V is step down first of all and then passed through full
wave rectification. Hence 220V is converted into 14V and then it is passes through Zener diode which
converts the voltage into 5V. Finally there is regulatorwhich converts the 5V into 3.2V where rest of the
circuit operates. There is varistor attached in the circuit which can withstand 1kV voltage and blow itself
saving the SMT PCB. There is EPROM which is called erasable programmable read-only memory for
saving the data regarding the meter. The data can be removed with the help of HV radiations. There is a
lithium battery of 3.6V which is non rechargeable for display when there is no power. MOV is micro-oxide
varistor which can withstand from 220V to 1KV saving the next PCB. There is a transmitter and receiver
on the meter so that readings can be read with the help of the Gauss meter. Moreover there are three
LEDs, one showing the fault in meter, one shows the power and one blinks 2400 times in a second. The
microcontroller is programmed with the help of programmer. The programmer have the capability to
program 2400 microcontrollers through its life span.
SMT process mainly depends upon three processes which are stuffing, soldering and cutting. All the
components are stuffed and then soldered and then extra soldering is removed along with the legs of
components. First of all, MOV, Resistor and Capacitor are stuffed, soldered and cut. After that three
crystal oscillators of 14.096 kHz along with the three capacitors (220𝜇𝐹, 25V) undergoes the same
process as the above components did. After that, super capacitor (.022 𝜇𝐹) along with the crystal
oscillator of 8 MHz are soldered. 6 pin connector along with three push buttons and crystal (32.329 MHz)
are stuffed and soldered. Finally the transmitter and receiver with battery and LCD are stuffed and
soldered. Moreover, Micro-switch along with the active led undermines the same process. The circuit
gets dead during the ultrasonic welding, so in order to save that crystal gums are used. Now the
microcontroller is pre-programmed and after testing it, all the readings are then kept to zero. Finally in
this department, SMT is carefully inspected and then sprayed to avoid corrosion. After testing it, the SMT
is send to the final assembly where it gets connected with the shunt.
Final Assembly:
In the final assembly, the terminal block is connected with the base along with the SMT board. The PCB is
modified so that it can connect with the shunt. The PCB is fitted to the base with the help pf screws. After
fitting the terminal block and PCB, the microcontroller is programmed with the ID and password. The ID
sequence and the password is generated with the help of pseudo random generator. So the password
and ID is random and it is literary impossible to trackit. After ID and password, the date and time is
checked so that allotment of password and ID becomes the part of record. Finally the program is load and
if somebody tries to open it other than authorized person, the LCD shows “open”. The program used for
this process is “Meter Management System” which tells the basic information i-e meter reading and
voltage etc. After final assembly, the static meter moves to “testing and calibration” department.

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Testing & Calibration:
In the testing and calibration, the meters are tested according to the requirements of the vendor. The
vendor has provided the “Claus1” which has five main factors. The meter is checked on the unity load,
then one the inductive and capacitive load. The signal phase can draw the 0.5A current into it whereas
the three phase meter can draw current up to 10A. Other than that, there aretwo types of meters which
are “LT” and “HT”. HT is used where high voltage is drawn whereas LT is used where high current are
drawn.
In the testing and calibration, the communication adaptor is placed along with the sensor with the LED.
When the sensor are matched, the A, B, C i-e for three phases arechecked, and the green light indicates
the perfect working of it and vice versa. Several readings are taken so that probability of error is
minimum. If any meter fails, it is sent to the recycling area, where error is detected and then sent it to the
particular department. Generally the problems in recycling area areof LED error, the one phase working
or any of three phase missing. There is “Tough meter” whom error can’t be rectified.
SPDP Department:
SPDP department stands for “Security packing and Dispatch packing “. The accuracy is kept at class 1
before dispatching it to the vendor i-e WAPDA. In SP department, the screws are tight ad rubber gas kit is
fitted so that dust and other environment factors wouldn’t affect the meter. Then, the meter top core is
fitted with the PEL plate. It is done with the help of PEL injection moulding and ploy carbonate materialto
make it rigid and unbreakable. After that, the screws aretight which can’t be unscrew due to led seal.
Ultrasonic welding is done for the top cover and bottom cover to make it unbreakable. For ultrasonic
welding machine, horns are used which high frequencies. As a result, heat is produced which causes
moulding. After packing, it is againtested by “quality insurance” department which is electronic testing
bench which shows two colours, blue for fine while red for fault. There is a documentation of error and
appraisals are given if a department produces minimum errors. In the dispatch department, cable guides
along with the leaflets areadded into packing box for lineman to operate.
Conclusion:
Thus making long story short, this report formally emphasizes the manufacturing process of the static
energy meter. It covers each and every aspect and narrates the process from the start till the dispatch of
it. This report covers a whole department working and experiences that are endured in it. Hence it was a
healthy experience with great knowledge and learning environment.