Training report

Orient Energy System
The University of Lahore 1

Dedication
We are dedicating our work to our parents and respected teachers, who have played a vital role in
our studies and have guided us at every step with their precious ideas. No doubt this dedication is
insufficient and we can never repay for the role they have played in our studies but we are sure
that their work will prove itself an asset in our life

Preface
Over the summer of 2015, I was granted the unique opportunity to be employed by Orient
Energy System limited as an Internee. Under the supervision of Electrical department I learn the
skills about electrical equipment just GE JENBACHER Engine. I was lucky enough to
undertake 7 weeks internship that expanded my skills and my way of thinking.
My main work was based on the Electrical discipline and primarily involved practical
understanding, basic theories under the supervision of concerned Engineers. I specially thank Sir
Shadab Gull Shab for their tireless efforts to help me understanding the difficult concepts which
are really hard to grasp.
I would like to express my deepest affection for my parents who prayed for my success and
encouraged me during this internship period.

Abstract:
This report is based on basic principles, working and manufacturing of different types of
Transformers used for Power Distribution.
Orient Energy Systems (PVT) Limited started its operation in the year 1996. Pursuant to the
Company’s philosophy, ‘Power for All’, Orient empowers people and their businesses by
bringing to them best global performers in the field of power generation and industrial solutions.
Our strength lies in our ability to understand market demands, keeping up with the changing
technological trends, building relationships and offering solutions, which are most dependable,
efficient and cost-effective. Our diverse client- base ranges from household consumers,
government bodies, local industries and multinational giants, displaying our capability and the
power of the brands that we represent. We have served in sectors such as, textiles,
pharmaceuticals, hospitals, telecom, oil & gas, hospitality, poultry farms, shopping malls,
educational institutes, commercial buildings and many more.

Table of Contents
Introduction of organization ............................................................................................................7
Mission and vision...........................................................................................................................8
Organizational chart........................................................................................................................9
Organization ..................................................................................................................................10
Departments ................................................................................................................................ 10
Project area of training...................................................................................................................11
Orient products and supports network….……………………………………......................................12
Gas engine………………………….…………………………………………………………………………………………………....13
General Principal ………………………………………………………………………………………………………………………………..13
4stroke principal…………………………………………………….………………………………………………………………...14
Engine parts ……………………………………………………………………………………………………………………………………….15
Product range ……………………………………………………………………………………………..………………….……...21
Salient features……………………………………………………………………………………………………..………….……..22
Schedule of internship program………………………………………………………………………………………………………..23
Implementation of theoretical knowledge ………………………………………………………………………………………..24
Parts of generators …………………………………………………………………………………………………………….…..24
Generator working ………………………………………………………………………………….……………………….…....32
Main components of a generator …………………………………………………………………………………..………33

Skills and techniques learnt during internship …………………………………………………………………………………37
Useful points of new internees …………………………………………………………………………………………………………..38
Suggestions/Recommendation…………………………………………………………………………………………………………...39
Conclusion …………………………………………………………………………………………………………………………………………..40

Introduction of Organization:
Orient Energy Systems (PVT) Limited is one of the leading multinational engineering companies
in Pakistan that is distributing internationally recognized power generation and industrial
solutions and services.
Orient Energy Systems (PVT) Limited started its operation in the year 1996. Pursuant to the
Company’s philosophy, ‘Power for All’, Orient empowers people and their businesses by
bringing to them best global performers in the field of power generation and industrial solutions.
Our strength lies in our ability to understand market demands, keeping up with the changing
technological trends, building relationships and offering solutions, which are most dependable,
efficient and cost-effective. Our diverse client- base ranges from household consumers,
government bodies, local industries and multinational giants, displaying our capability and the
power of the brands that we represent. We have served in sectors such as, textiles,
pharmaceuticals, hospitals, telecom, oil & gas, hospitality, poultry farms, shopping malls,
educational institutes, commercial buildings and many more.

Mission & Vision
 Mission:
Do not market-product or services but always strive to market benefits and
satisfaction to its clients.
 Vision:
Always think beyond the Product & Service being rendered and consider what the
consumer is actually buying and his reasoning behind that purchase.

Organizational chart

Organization
Orient Energy Systems has a very dynamic and progressive management structure in
line with industry practices. Component human resources from within the company have fueled
termed our customers has been complied to change their purchasing habits. Orient growth by
excelling in functional management. Energy Systems responds to this challenge of providing
best services to customers based on convenience and in line with customer requirement. The
company has a large pool of professionals in all departments which contributes to the effort sin
selling, services and support. A thorough study of the organization reveals that the hierarchy is a
blend of centralized and de-centralized. Middle and lower level managers and officers have a
medium degree of autonomy in making routine decisions and taking controlled risks. The benefits of
this approach are evident from the fast and continuous growth of the organization in recent years
D e p a r t m e n t s
The organization has been divided into departments based on business areas:
 Gas generator sales
 Diesel Generator Sales
 Chiller Sales
 Compressors Sales
 Machinery Sales
 Large Power project sales / Special project sales
 Engineering / Technical
 Parts Sales
 Product Support Services
 M Sales and Service

Project area of training
GE JENBACHER Gas Engine
GE JENBACHER is a leading Gas genset manufacturer in Austria ranked 1st in the world’s Gas
gen set industry. Its gas engine division is one of the world’s leading manufacturers of gas-fueled
reciprocating engines, packaged generator sets and cogeneration units for power generation.
In Pakistan, the gen sets range in power from 0.33 to 4.4MW which can be run either on natural
gas or a variety of other gases such as biogas, coal mine gas, sewage gas and combustible
industrial waste gases.
Patented combustion systems, engine controls and monitoring enable its power generation plants
to meet stringent emission standards whilst offering high levels of efficiency, durability and
reliability.
With more than 50 years of experience in gas genset manufacturing, GE Jenbacher offers world
leading technical support for each of its products.

Orient product supports network
Orient Energy Systems has the best product support infrastructure in power & industrial
engineering solutions in Pakistan.
With ‘round the clock’ services and internationally trained service engineers along with well-
equipped workshops and spare parts inventory, we excel at catering to urgent needs of our
customers.

Gas Engine
GE JENBACHER gas engine used the LEAN-OX method, which is the further development of
the lean-mix engine principal here the engine is supplied with the mixer of gas and a surplus of
air to minimize emission already at combustion stage in the engine.
General Principal:
The GE JENBACHER gas engine work on the four stroke principal and is water cooled 20
cylinders V-engine (70%) with an exhaust gas turbo charger for pressure charging of the intake
mixer.

Four stroke Principal:
1. Intake Inlet stroke
2. Compression stroke
3. Power stroke
4. Exhaust stroke
 INTAKE:
This stroke of the piston begins at top dead center. The piston descends from the top of
the cylinder to the bottom of the cylinder, increasing the volume of the cylinder. A
mixture of fuel and air is forced by atmospheric (or greater) pressure into the cylinder
through the intake port.
 COMPRESSION:
With both intake and exhaust valves closed, the piston returns to the top of the cylinder
compressing the air or fuel-air mixture into the cylinder head.
 POWER:
This is the start of the second revolution of the cycle. While the piston is close to Top
Dead Centre, the compressed air–fuel mixture in a gasoline engine is ignited, by a spark
plug in gasoline engines, or which ignites due to the heat generated by compression in a
diesel engine. The resulting pressure from the combustion of the compressed fuel-air
mixture forces the piston back down toward Bottom Dead Center
 EXHAUST:
During the exhaust stroke, the piston once again returns to top dead center while the
exhaust valve is open. This action expels the spent fuel-air mixture through the exhaust
valve.

Engine parts:
1. Throttle valve
2. Turbo charger
3. Air-intake line
4. Engine cooling water return line
5. Ignition coil (convert 24v to 18kv)
6. Exhaust valve
7. Piston
8. Cylinder
9. Con necking rod
10. Piston cooling nozzle
11. Crankshaft
12. Engine oil pump
13. Injection tank.

1. Throttle valve
When gas is complete 100% then other gas should go to the turbo charge by pass where
the gas reaches the turbo charger.
2. Turbo charger
Turbo charger is use to raise the efficiency. There are 2 fans in this turbo charge.
One is move clock wise and 2nd is move anti-clock wise. Clock wise fan push the gas
inside the engine and anti-clock wise fan exhaust the extra air.

3. Air-intake line
Where the fresh natural air intake inside the engine and mix with the gas.
4. Engine water return line:
The air which intake in air intake line, this air use the cool the engine all lines and return
to the cooling water.

5. Ignition coil:
Ignition coil use to converts 24v to 18kv which we take from batteries.
6. Exhaust valve:
Exhaust valve use to exhaust the gas which created during engine working.
7. Piston:
A piston is a component of reciprocating engines, reciprocating pumps, gas compressors
and pneumatic cylinders, among other similar mechanisms. It is the moving component
that is contained by a cylinder and is made gas-tight by piston rings.

8. cylinder
There are 20 cylinders in this gas engine. In this there is spark plugs use to sparkblast for
ignition..
Cylinder sparking sequence:
[ 1 7 3 9 5 10 4 8 2 6 ]
[17 13 19 15 20 14 18 12 16 11 ]
9. Connecting Rod.
A connecting rod is an engine component that transfers motion from the piston to the
crankshaft and functions as a lever arm.

10. Piston cooling nozzle:
It is a little nozzle which is pointed towards the beneath of a piston in an internal
combustion.
It is linked to the pressurized side of the oil system, so cool oil coming directly from the
oil cooler will spray onto the piston and cooling it instead of just cooling around the
cylinder.

Product range
Model Voltage of Generation Power Range (kW @ISO)
JGS 208 400 V 330
JGS 312 400 V 635
JGS 316 400 V 834
JGS 320 400 V / 11000 V 1063 / 1053
JGS 412 400 V 844
JGS 416 400 V / 11000 V 1127 / 1126
JGS 420 400 V / 11000 V 1410 / 1409
JGS 612F 400 V / 11000 V 2006 / 2003
JGS 616F 11000 V 2677
JGS 620F 11000 V 3352
JGS 624G 11000 V 4029
JGS 624H 11000 V 4375

Salient features
 Most efficient gas engine – best fuel consumption in its class.
 Can run on a variety of combust able gases.
 Low vibration – only 3% dynamic load.
 Smaller in size and lighter in weight.
 State-of-the-art Le-Nox system to control air fuel ratio.
 Control system designed, produced and tested by GE Jenbacher.
 Can run on power & island mode.
 Longer maintenance intervals – 30,000 hrs. top end overhaul and 60,000 hrs. major
overhaul.
 GEJ’s worldwide experience in natural gas as well as non-natural gas engines.
 Orient’s product support coverage all over Pakistan.
 Manufacturer’s warranty

Schedule of internship program
Total period of time 2months
I worked on GE JENBACHER Gas Engine

Implementation of theoretical knowledge
PARTS OF GENERATOR
 Batteries
 Filters
 Crank shaft
 Radiator
 Piston
 Turbo
 Rotor
 Rectifier
 Emergency switch
 Relay
 Breaker
 Oil sensor
 Water sensor
 Self-Starter

BATTERIES
A battery-powered generator works by using the electricity stored in a battery to provide
alternative power to one or more systems that normally work off the main power grid. Because
the energy is stored and is immediately available, battery generator can provide instant cut-over
for a failed circuit, with no time spent finding fuel or turning the generator on.
FILTERS
 Air Filters
 Engine Oil Filters
Air Filters:
Designed for maximum protection of vital engine parts and optimum performance:
 Standard efficiency filters - durable construction to handle the most rugged applications with the
best capacity in the industry.
 Ultra-high efficiency filters- the best early hour efficiency filters with the longest life available
for your Cat equipment.

Engine Oil Filters:
Designed to maximize engine and engine oil cleanliness, meet expected oil interval changes, and
provide the best machine performance and component protection.
CRANK SHAFT
The crankshaft is located in the engine of a vehicle and converts the force created by the engine's
pistons moving up and down into a force that moves the wheels in a circular motion so the car
can go forward. Located inside the car's engine,
It is connected to all the pistons in the engine and to the flywheel. To understand this
Shaft, it is important to understand how the pistons and the flywheel work.
RADIATOR
Radiator cooling is the most common method of cooling gen set engines. Simple and practical,
they fit most applications’ needs. All gen sets can be equipped with various sizes of radiators
mounted on the front of the unit. However, remote radiators can be used when adequate airflow
through the gen set enclosure is not possible.

PISTON
A piston is a cylindrical piece of metal that moves up and down inside the cylinder.
The core of the engine is the cylinder, with the piston moving up and down inside the cylinder.
The engine described above has one cylinder. That is typical of most lawn mowers, but most
cars have more than one cylinder (four, six and eight cylinders are common). In a multi-cylinder
engine, the cylinders usually are arranged in one of three ways: inline, V or flat.
Piston rings provide a sliding seal between the outer edge of the piston and the inner edge of the
cylinder. The rings serve two purposes:
 They prevent the fuel/air mixture and exhaust in the combustion chamber from leaking into the
pump during compression and combustion.
 They keep oil in the pump from leaking into the combustion area, where it would be burned and
lost.
TURBO

A turbo can significantly boost an engine's horsepower without significantly increasing its
weight, which is the huge benefit that makes turbo so popular.
They compress the air flowing into the engine. The advantage of compressing the air is that it
lets the engine squeeze more air into a cylinder, and more air means that more fuel can be added.
Therefore, you get more power from each explosion in each cylinder. A turbocharged engine
produces more power overall than the same engine without the charging. This can significantly
improve the power-to-weight ratio for the engine.
The rotor or the field coils in a generator produce the magnetic flux that is essential to the
production of the electric power. The rotor is a rotating electromagnet that requires a DC (Direct
Current) electric power source to excite the magnetic field. This power comes from an exciter.
In earlier days, the exciter was a small DC generator coupled to the same shaft as the rotor.
Therefore, when the rotor rotates this exciter produces the power for the electromagnet. Control
of the exciter output is done by varying the field current of the exciter. This output from the
exciter then controls the magnetic field of the rotor to produce a constant voltage output by the
generator. This DC current feeds to the rotor through slip rings.
ROTOR
The rotor is the moving part of a rotary electric motor, electric generator or alternator, which
rotates because the wires and magnetic field of the motor are arranged so that a torque is
developed about the rotor's axis. In some designs, the rotor can act to serve as the motor's
armature, across which the input voltage is supplied.

RECTIFIER
Rectifier diodes are electronic devices that allow electrical current to flow in one direction only.
Because of this electrical property, diodes are used to convert alternating current electrical
energy into direct current electrical energy. In an automotive electrical system, diodes can be
found in several places, including the alternator. Alternator diodes perform three critical
functions for the automotive charging system.
EMERGENCY SWITCH
A transfer switch is an electrical switch that switches a load between two sources. Some transfer
switches are manual, in that an operator affects the transfer by throwing a switch, while others
are automatic and switch when they sense one of the sources has lost or gained power.
RELAY

Electromechanical protective relays operate by either magnetic attraction, or magnetic induction.
Unlike switching type electromechanical relays with fixed and usually ill-defined operating
Voltage thresholds and operating times, protective relays have well-established, selectable and
adjustable time/current (or other operating parameter) operating characteristics) We can say that
relay is a sensing device.
Breaker
A circuit breaker is an automatically operated electrical switch designed to protect an electrical
circuit from damage caused by overload or short circuit. Its basic function is to detect a fault
condition and interrupt current flow. Unlike a fuse, which operates once and then must be
replaced, a circuit breaker can be reset (either manually or automatically) to resume normal
operation. Circuit breakers are made in varying sizes, from small devices that protect an
individual household appliance up to large switchgear designed to protect high voltage circuits.
OIL SENSOR
Sensor is connected on the oil path, which will measure the pressure of oil.
It will indicate the pressure as well as alarming and switched off the dg if pressure is low.

WATER SENSOR
This sensor is used for protection purpose when water is heated nearly 120o c they can send a
signal to module for turn off the generator. This sensor is work on 24 volts.
Self-Starter
The starter motor converts electrical energy to mechanical energy and is mounted on the cylinder
block in position to engage a ring gear on the engine fly wheel.
Starting is usually accomplished by the operator activating a starter switch as part of ignition key
operation. This allows a relatively small current to flow to a starter solenoid relay and operate a
plunger attached to a drive pinion engagement lever.
The plunger movement engages the drive pinion with the ring gear and closes a set of heavy duty
contacts, allowing a large current to flow from the battery to the starter motor, rotating the
armature and drive pinion, and causing the crankshaft to spin.
When the engine starts and is able to run on its own, the operator usually releases the key and
this withdraws the pinion from the ring gear and brings the armature to a halt.

Generator working
An electrical generator is a device that converts mechanical energy obtained from an external
source into electrical energy as the output.
It is important to understand that a generator does not actually ‘create’ electrical energy. Instead,
it uses the mechanical energy supplied to it to force the movement of electric charges present in
the wire of its windings through an external electric circuit.
This flow of electric charges constitutes the output electric current supplied by the generator.
This mechanism can be understood by considering the generator to be analogous to a water
pump, which causes the flow of water but does not actually ‘create’ the water flowing through it.
The modern-day generator works on the principle of electromagnetic induction discovered by
Michael Faraday in 1831-32. Faraday discovered that the above flow of electric charges could be
induced by moving an electrical conductor, such as a wire that
Contains electric charges, in a magnetic field. This movement creates a voltage difference
between the two ends of the wire or electrical conductor, which in turn
Causes the electric charges to flow, thus generating electric current.

MAIN COMPONENTS OF A GENERATOR
The main components of an electric generator can be broadly classified as follows (refer to
illustration above:
 Alternator
 Fuel System
 Cooling and Exhaust Systems
 Lubrication System
 Battery Charger
 Control Panel
 Main Assembly / Frame
A description of the main components of a generator is given below.

ALTERNATOR
The alternator, also known as the Generator head’, an alternator, electricity produce when
magnetic field spins inside the stator winding.
COOLING & EXHAUST SYSTEMS
Cooling System Continuous usage of the generator causes its various components to get heated
up. It is essential to have a cooling and ventilation system to withdraw heat produced in the
process.
Raw/fresh water is sometimes used as a coolant for generators, but these are mostly limited to
Specific situations like small generators in city applications or very large units over 2250 kW
and above. Hydrogen is sometimes used as a coolant for the stator windings of large generator
units since it is more efficient at absorbing heat than other coolants. Hydrogen removes heat
from the generator and transfers it through a heat exchanger into a secondary cooling circuit that
contains de-mineralized water as a coolant. This is why very large generators and small power
plants often have large cooling towers next to them. For all other common applications, both
residential and industrial, a standard radiator and fan is mounted on the generator and works as
the primary cooling system.
It is essential to check the coolant levels of the generator on a daily basis. The cooling system
and raw water pump should be flushed after every 600 hours and the heat exchanger should be
cleaned after every 2,400 hours of generator operation.
LUBRICATING SYSTEM
Since the generator comprises moving parts in its engine, it requires lubrication to ensure
durability and smooth operations for a long period of time. The generator’s engine is lubricated
by oil stored in a pump. You should check the level of lubricating oil every 8 hours of generator
operation. You should also check for any leakages of lubricant and change the lubricating oil
every 500 hours of generator operation.

BATTERY CHARGER
The start function of a generator is battery-operated. The battery charger keeps the generator
battery charged by supplying it with a precise ‘float’ voltage. If the float voltage is very low, the
battery will remain undercharged. If the float voltage is very high, it will shorten the life of the
battery. Battery chargers are usually made of stainless steel to prevent corrosion. They are also
fully automatic and do not require any adjustments to be made or any settings to be changed. The
DC output voltage of the battery charger is set at 2.33 Volts per cell, which is the precise float
voltage for lead acid batteries. The battery charger has an isolated DC voltage output that does
interfere with the normal functioning of the generator.
CONTROL PANEL
This is the user interface of the generator and contains provisions for electrical outlets and
controls. The following article provides further details regarding the generator control
panel. Different manufacturers have varied features to offer in the control panels of their units.
Some of these are mentioned below.
(a) Electric start and shut-down – Auto start control panels automatically start your generator
during a power outage, monitor the generator while in operation, and automatically shut down
the unit when no longer required.

(b) Engine gauges – Different gauges indicate important parameters such as oil pressure,
temperature of coolant, battery voltage, engine rotation speed, and duration of operation.
Constant measurement and monitoring of these parameters enables built-in shut down of the
generator when any of these cross their respective threshold levels.
(c) Other controls – Phase selector switch, frequency switch, and engine control switch (manual
mode, auto mode) among others.

Skill and Techniques during internship
Internships will provide students the opportunity to test their interest in a particular career
before permanent commitments are made.
Internship students will develop skills and techniques directly applicable to their careers.
Internships will aid students in adjusting from college to full-time employment.
Internships will provide students the opportunity to develop attitudes conducive to effective
interpersonal relationships.
Internships will increase a student's sense of responsibility.
Internship students will be prepared to enter into full-time employment in their area of
specialization upon graduation.
Internship students will acquire good work habits.
Internships will provide students with the opportunity to earn a salary while pursuing educational
goals.
Internship students will develop employment records/references that will enhance employment
opportunities.
Internships will provide students with an in-depth knowledge of the formal functional activities
of a participating organization.
Internships will provide students the opportunity to understand informal organizational
interrelationships. Internship programs will enhance advancement possibilities of Graduates.

USEFUL POINTS FOR NEW INTERNEES:
New internees should follow these points
 Be responsible, adopt a good work attitude
 Be on time
 Meet your deadlines
 Take your assignments(tasks) seriously
 Avoid doing your personal social interaction
 Avoid blogging about your workplace, colleagues or company projects. Some
information may be confidential to the company and any leakage may lead to serious
consequences.
 Be proactive
 Always follow the rules and regulations of company

SUGGESTIONS/RECOMMENDATIONS:
 The salaries of the employees should be reasonable.
 There should be screening of employees because the no of employees working is more
than required.
 Overall system should be computerized to save time, money and resources of the
 Organization must have to introduce automation in its processes and improve system.
The HR department should play an effective role. Proper Arrangement should be made
for professionals by issuing detailed job description and job specification to get
maximum profit from them.

CONCLUSION:
Now-a-days, one thing many Pakistani business organizations agree on is the deleterious
effects of uncertain future on their business. With the rapidly changing market place owing to
breakthroughs in technologies, lowering of barriers to international competition and maturing of
Pakistani consumers, this uncertainty is only going to increase. In such ruthless scenario, only
the nimble and sue-footed who have the ability to correctly read the changes in consumer
preferences before their competitors do and who have the systems to quickly respond with better
value proposition will succeed. Pell is equal to the task; it is providing a world class professional
base in the field of consultancy engineering to the employees, and also introduces the modern
technology and quality improvement program for the experts.
In the end, we conclude from this report that NSI is a multi-disciplinary consultancy
company that has evolved a divisional organization structure suited to its specific needs. NSI
goal is to attain self-reliance in engineering consultancy and replace foreign consultants.
Consequently, we can say that NSI has an excellent management system to meet the current
challenges.

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