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 Training report
1. Orient Energy System The University of Lahore 1
2. Orient Energy System The University of Lahore 2 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
3. Orient Energy System The University of Lahore 3 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.
4. Orient Energy System The University of Lahore 4 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.
5. Orient Energy System The University of Lahore 5 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
6. Orient Energy System The University of Lahore 6 Skills and techniques learnt during
internship …………………………………………………………………………………37 Useful points
of new internees
…………………………………………………………………………………………………………..38
Suggestions/Recommendation…………………………………………………………………………………………………………...39
Conclusion
…………………………………………………………………………………………………………………………………………..40
7. Orient Energy System The University of Lahore 7 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.
8. Orient Energy System The University of Lahore 8 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.
9. Orient Energy System The University of Lahore 9 Organizational chart
10. Orient Energy System The University of Lahore 10 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
11. Orient Energy System The University of Lahore 11 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.
12. Orient Energy System The University of Lahore 12 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.
13. Orient Energy System The University of Lahore 13 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.
14. Orient Energy System The University of Lahore 14 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.
15. Orient Energy System The University of Lahore 15 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.
16. Orient Energy System The University of Lahore 16 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.
17. Orient Energy System The University of Lahore 17 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.
18. Orient Energy System The University of Lahore 18 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.
19. Orient Energy System The University of Lahore 19 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.
20. Orient Energy System The University of Lahore 20 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.
21. Orient Energy System The University of Lahore 21 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
22. Orient Energy System The University of Lahore 22 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
23. Orient Energy System The University of Lahore 23 Schedule of internship program Total
period of time 2months I worked on GE JENBACHER Gas Engine
24. Orient Energy System The University of Lahore 24 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
25. Orient Energy System The University of Lahore 25 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.
26. Orient Energy System The University of Lahore 26 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.
27. Orient Energy System The University of Lahore 27 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
28. Orient Energy System The University of Lahore 28 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.
29. Orient Energy System The University of Lahore 29 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
30. Orient Energy System The University of Lahore 30 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.
31. Orient Energy System The University of Lahore 31 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.
32. Orient Energy System The University of Lahore 32 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.
33. Orient Energy System The University of Lahore 33 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.
34. Orient Energy System The University of Lahore 34 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.
35. Orient Energy System The University of Lahore 35 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.
36. Orient Energy System The University of Lahore 36 (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.
37. Orient Energy System The University of Lahore 37 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.
38. Orient Energy System The University of Lahore 38 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
39. Orient Energy System The University of Lahore 39 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.
40. Orient Energy System The University of Lahore 40 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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