Professional Documents
Culture Documents
ON
STUDENTS’ INDUSTRIAL WORK EXPERIENCE SCHEME (SIWES)
PREPARED BY
GODWIN PAUL
LEVEL: 400
HELD AT:
SUBMITTED TO:
Faculty of Technology,
University of Ibadan,
Ibadan.
The Director,
University of Ibadan,
Ibadan.
Dear Sir,
This is to inform you that the report work which covered twenty four (24) weeks spent
at the Ministry of Agriculture and Natural Resources was compiled and completed by
me.
I therefore submit the report work as partial fulfillment of the requirement for the
Student Industrial Work Experience Scheme of the University of Ibadan.
Yours faithfully,
Godwin Paul
207308
ii
ABSTRACT
This report covers a review of work taken during the student industrial work
experience scheme at the Ministry of Agriculture and Natural Resources State
Secretariat Ibadan. The report shows the experiences gained during the work period of
six months.
Conclusively, the training program helped me understand the practical aspect of what
is learnt in the classroom. The knowledge gained will go a long away to building a
career as an Agricultural and Environmental Engineer.
iii
ACKNOWLEDGEMENTS
My sincere gratitude goes to God Almighty who has given me the privilege to
complete this programme.
I also appreciate and thank the director of the Student Industrial Work Experience
Scheme and his team for the successful assessments of my training.
My regards also goes to my industrial based supervisor and all the Ministry of
Agriculture and Natural Resources staff for their necessary supervision and useful
information provided.
I cannot forget my loving and caring family for their support both spiritually and
financially during my SIWES programme, may God bless you all.
iv
Table of Contents
Title Page……………………………………………………………………………......i
Submission Letter………………………………………………………………………………ii
Abstract…………………………………………………………………………………...……iii
Acknowledgements………………………………………………………………………….…iv
Chapter 1 STUDENT INDUSTRIAL WORK EXPERIENCE SCHEME ................................. 1
1.1 INTRODUCTION ............................................................................................................. 1
1.2 BACKGROUND OF SIWES............................................................................................ 1
1.3 OBJECTIVES OF STUDENT INDUSTRIAL WORK SCHEME ................................... 2
Chapter 2 AIR CONDITIONING AND REFRIGERATION ..................................................... 3
2.1 INTRODUCTION ............................................................................................................. 3
2.2 AIR CONDITIONING ...................................................................................................... 3
2.2.1 Types of Air Conditioning Systems ........................................................................... 3
2.5.3 Pressure washing the air-filters of the indoor and outdoor units .............................. 10
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Chapter 3 HEAVY DUTY MACHINES .................................................................................. 21
3.1 INTRODUCTION ........................................................................................................... 21
3.2 TRACTORS .................................................................................................................... 21
3.2.1 Daily / Everyday (After 8-10 hours of work) ........................................................... 21
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List of Figures
Figure 1. Window Ac Unit .............................................................................................. 3
Figure 2. Ductless Mini - Slit, Indoor Unit ..................................................................... 5
Figure 3. Ductless Mini – Split, Outdoor Unit ................................................................ 5
Figure 4. Manifold Gauge To Be Used For Recharging. The Blue Side Is Linked To
The Low Pressure Side Of The Outdoor Unit And The Yellow Line To The
Refrigerant Tank. ............................................................................................................ 9
Figure 5. A Charging Set-Up Using Manifold Gauge .................................................. 10
Figure 6. Mounting Plate After Being Screwed To The Wall ...................................... 12
Figure 8. End Of The Tube Connected To The Compressor ........................................ 19
Figure 7. Copper Tubes Wound Round The Inner Compartment ................................. 19
Figure 9. Weed Slasher ................................................................................................. 25
Figure 10. Damaged Clutch Release Bearing Before Removal .................................... 26
Figure 11. A Tractor After Being Separated For Clutch Bearing Replacement ........... 27
vii
CHAPTER 1
1.1 INTRODUCTION
SIWES stands for Student Industrial Work Experience Scheme which was established
by the Industrial Training Fund in 1973 in order to widen the horizon so as to ensure
that Students have technical knowledge or working experience before graduating from
their various institutions. This helps to bridge the gap between practical skills and
theoretical knowledge and enable Students to cope effectively in the industrial world.
The scheme exposes Students to industrial skills necessary to bring up ideas in areas of
machineries, structures, implements to make work easier, making use of the available
resources. The Scheme also helps Students to develop occupational competencies so as
to be able to contribute their quota to the national economy and technological
development of the Nation after graduation.
ITF solely funded the scheme during its initial years of being formed but as time went
on, it became unbearable for funding and withdrew from the scheme in 1978. In 1979,
the federal government handed over the scheme to both the National University
Commission (NUC) and the National Board for Technical Education (NBTE). ITF
later was given management and implementation of the scheme by the federal
government in 1984. It was effectively taken over by the Industrial Training Fund
(ITF) in July 1985 with funding solely borne by the federal government.
1
one of the accepted skill training programmes that a student must undergo in order to
achieve a minimum academic standard in various degree programmes for all Nigerian
universities. Prior to this period, the Industrial Training Fund (ITF) and National
Universities Commission (NUC) funded the scheme to cater for the training of
students for man power development for the industrial sector and establishments.
2. To prepare Students for Industrial Work situation they are likely to meet after
graduation.
7. To enable professionals, assess students real work capabilities which may serve
as an avenue for recruitment.
2
CHAPTER 2
2.1 INTRODUCTION
I was introduced to the section of the department responsible for the repair,
maintenance and installation of air conditioners. In the course of my attachment, I was
involved in troubleshooting and repairs of air conditioning (A.C ) units.
There have been so many developments on air conditioning systems over the years,
during my attachment; I was exposed to the Stand alone AC units and the Split system
AC units.
In stand-alone AC units, both coils are inside one device (usually located inside the
house). An example of this type of air conditioner is the Window AC unit.
Window AC unit
A window air conditioner is a single unit with all of its components enclosed
3
inside. It ejects heat out of its outdoor side and blows cool air into the room on the
indoor side. As the name suggests, it is installed in a window or by making a hole
in the wall. Such air conditioners have a filter that slides out so that it can be
cleaned regularly for full AC efficiency. These air conditioners have controls on
the unit & may also come with a remote. Since Window air conditioners come in
different sizes, they would be suitable if you‟re looking to cool a single room or a
small area. If you go for a large window air conditioner you can even cool a small
home considering it is a single story or one open space.
b. Simple to install.
c. Easy to maintain.
a. Can be noisy during operation & are visible from outside the home.
b. They obscure the view from a window and must be located close to a suitable
electrical outlet.
c. Not all windows support air conditioners, some window ACs are not suitable
for casement or irregularly shaped windows.
Split-system air conditioners are comprised of two shells. The one inside the house is a
smaller quiet shell, and the bigger noisier one is outside.
That means that the cooling coil is inside the house and the heating coil that dispenses
heat and the compressor are outside the house. An example of the split system AC unit
is the Ductless Mini – Split.
4
Ductless Mini – Split
For better efficiency, or you want to do away with a lot of ducting, or you simply just
want a portion of your home to be cooled, then opting for ductless mini-split air
conditioners is a great choice.
5
cooling purposes. Such types of air conditioners are regarded much more efficient in
energy consumption compared to some of the other options available.
Ductless mini-splits come with a remote control but coupled with a smart AC
controller you can operate using your phone, from anywhere.
a. A single ductless mini-split unit is not enough for cooling large homes.
Evaporator - Receives the liquid refrigerant. It is loosely called the indoor unit.
The cold side of an air conditioner contains the evaporator and a fan that blows
air over the chilled coils and into the room. The refrigerant experiences a
pressure drop once in the evaporator. It expands and changes back into gas.
Condenser - Facilitates heat transfer. It is loosely called the outdoor unit. The
hot side contains the compressor, condenser and another fan to vent hot air
coming off the compressed refrigerant to the outdoors.
6
Compressor - A pump that pressurizes refrigerant. The compressor is actually a
large electric pump that pressurizes the refrigerant gas as part of the process of
turning it back into a liquid. There are mostly two types of compressors used in
AC units. They are Reciprocating compressors and Rotary compressors. But
modern Ac units these days come with Rotary compressors.
Air handler and blowing unit - This air conditioner components work together
to draw the air to the evaporator and distribute cool air over the room. A duct
system facilitates the passage of airflow in the room.
The basic operation an air conditioner has to perform is to cool the indoor air. That's
not all it does, though. Air conditioners monitor and regulate the air temperature via a
thermostat. They also have an onboard filter that removes airborne particulates from
the circulating air. Air conditioners function as dehumidifiers. Because temperature is
a key component of relative humidity, reducing the temperature of a volume of humid
air causes it to release a portion of its moisture. That's why there are drains and
moisture-collecting pans near or attached to air conditioners, and why air conditioners
discharge water when they operate on humid days.
2.3.1 Refrigerant
A refrigerant is a substance or mixture, usually a fluid, used in an air conditioner. In its
cycles, it undergoes phase transitions from a liquid to a gas and back again.R22
refrigerants are preferred due to their ozone-friendly nature.
2.3.2 Lubricant
This is otherwise called compressor oil. As it name implies, it is fed into the
compressor. Compressor oil is a necessary component in any air conditioning system.
There are three main purposes of the oil. They are used for lubrication, removal of heat
and for sealing.
7
2.4 WORKING PRINCIPLES OF AN AIR CONDITIONING SYSTEM
Irrespective of the particular model in question, air conditioners have a common basic
working principle.
Air conditioners use refrigeration to chill indoor air, taking advantage of a remarkable
physical law: When a liquid converts to a gas (in a process called phase conversion), it
absorbs heat. Air conditioners exploit this feature of phase conversion by forcing
special chemical compounds (Refrigerants) to evaporate and condense over and over
again in a closed system of coils (In a cyclic process)
The compounds involved are refrigerants that have properties enabling them to change
at relatively low temperatures. Air conditioners also contain fans that move warm
interior air over these cold, refrigerant-filled coils. In fact, central air conditioners have
a whole system of ducts designed to funnel air to and from these serpentine, air-
chilling coils.
When hot air flows over the cold, low-pressure evaporator coils, the refrigerant inside
absorbs heat as it changes from a liquid to a gaseous state. To keep cooling efficiently,
the air conditioner has to convert the refrigerant gas back to a liquid again. To do that,
a compressor puts the gas under high pressure, a process that creates unwanted heat.
All the extra heat created by compressing the gas is then evacuated to the outdoors
with the help of a second set of coils called condenser coils, and a second fan. As the
gas cools, it changes back to a liquid, and the process starts all over again. Think of it
as an endless, elegant cycle: liquid refrigerant, phase conversion to a gas/ heat
absorption, compression and phase transition back to a liquid again.
It's easy to see that there are two distinct things going on in an air conditioner.
Refrigerant is chilling the indoor air, and the resulting gas is being continually
compressed and cooled for conversion back to a liquid again.
8
refrigerant topped up).To achieve this check, I had to carry out the soap bubble test.
The solution of soap and water is the easiest leak detector. To carry out this approach
Simply apply the soapy water to the suspected area with a brush or spray bottle and
look for the presence of bubbles or foam, which would be caused by a leak. As advised
by my industry based supervisor, I concentrated more on the welded joints as they
were prone to failure than other parts of the piping network. The problem with this
method is that it is only useful for a large leak.
Figure 4. manifold gauge to be used for recharging. The blue side is linked to the
low pressure side of the outdoor unit and the yellow line to the refrigerant tank.
9
Figure 5. A charging set-up using manifold gauge
2.5.3 Pressure washing the air-filters of the indoor and outdoor units
The air filter is a very vital component of the AC. It is responsible for preventing dust
particles into the core of the AC. This is very important in other to stall a breakdown
of the system. But in a case where the air filter becomes clogged, then the AC
efficiency is greatly reduced. Air conditioning filters can play a big role in an air
conditioning water leak. First is that the dirty filter blocks the air from penetrating
through the filter. When the air can‟t go through the filter, it starts to freeze. Once the
ice melts, the water then drips. A most likely symptom of a clogged air filter is that the
blowing effect of the fan and by extension cooling will not be felt (When the fan has
been determined to be in good condition).
So as preventive measure, the air filters are removed and pressure washed with the aid
of a Pressure washing machine (Popularly called a steaming machine).
10
Your AC capacitor will be either a dual capacitor or a single capacitor. A dual
capacitor has three sets of terminals on top: one for the compressor, one for the fan,
and a shared “common” terminal for both to use. A single capacitor only has two
terminals, and if your unit uses single capacitors, you probably have two of them in
your system (one for the compressor and one for the fan). Most times faulty capacitors
appear bulgy or even ruptured
A faulty capacitor means the unit‟s fan or blower will not function effectively as there
will not be enough voltage to start the fan motor. Even when they stutter and start, they
shut down in the shortest run. A good way to diagnose this problem might also be to
listen out for hum or click noise emanating from the unit.
We selected an unobstructed location on the interior walls of the office to mount the
indoor air conditioning unit. While considering this various factors.
Avoid locations where gas may leak or where oil mist or Sulphur exists.
Install the unit at least 3.3 feet (1 m) away from antenna, power or
connecting lines that are used for television, radio, home security
11
systems, intercoms or telephones. The electrical noise from these
sources could cause operational problems for your air conditioner.
We held the mounting plate against the wall where we wanted to install
the indoor unit.
We the used a level to make sure the plate was both horizontally and
vertically square. We also used markers to make inscriptions on the
wall in other to help subsequent drilling.
We then drilled holes into the wall at the appropriate spots to affix the
plate to the wall.
We inserted plastic anchors into the holes. We then secured the plate to
the wall with tapping screws.
We found the best spot for the hole to the exterior based on the opening
in the mounting bracket. Special consideration was given to the length
of the pipe and the distance that it needed to travel to reach the outside
12
unit.
We then drilled a hole that is 7.5 cm in diameter through the wall. The
hole was initiated to slope downward toward the exterior to ensure
adequate drainage.
The unit‟s front panel was lifted and the cover removed.
We made sure the cable wires were connected to the screw terminals.
And also, make sure that they match the diagram (i.e. owner‟s manual)
that comes with the unit.
We ran the piping from the indoor unit toward the hole drilled through
the wall taking care to minimize bending to ensure that the unit
performs well.
We then placed the pipe cap on the interior end of the PVC pipe. We
also inserted the pipe into the hole in the wall.
The copper pipes were binded, the power cables and the drain pipe
together with electrical tape. As a matter of design, we placed the drain
pipe on the bottom to ensure a free flow of water.
We then secured the pipe to the indoor unit, using 2 wrenches, working
in opposite directions, to tighten the connection.
We then joined the water drainage pipe to the indoor unit‟s base.
We ran the bound pipes and cables through the hole in the wall, making
sure that the drainage pipe allows water to drain in an appropriate place.
13
2. Installing the outdoor unit
The concrete pad is laid high enough so that the condenser will sit conveniently
above ground level (Even though this is especially important for areas with
snow).
The outdoor condenser was set on top of the pad, using rubber
cushioning under the unit's feet to minimize vibration.
We referred to the unit‟s wiring diagram and made sure the cable wires
are connected as the diagram suggests. Following the manufacturer's
instructions for wiring is crucial.
I fastened the cables with a cable clamp and replace the cover.
Secure the pipes‟ flare nuts to the corresponding pipes on the outdoor
unit.
14
We affixed the piping to the wall with clamps.
Condenser -These are the multiple tubes and fins that are seen outside of
refrigerator. All the heat absorbed by refrigerant is thrown off by Condenser in
the cooling system. Surface area is increased for maximum heat transfer. As
the refrigerant passes through these coils it is cooled down and condenses, heat
is transferred to the surrounding air.
Evaporator - It is the main internal cooling part of the refrigerator in the forms
of small tubes made from copper or aluminum. These coils are made of high
thermal metal conductivity metal to maximize heat transfer. As the refrigerant
turns from a liquid into a gas through evaporation, it cools the area around it.
15
Evaporator absorbs the heat from foods put in the cooling sections.
16
2.7.3 Symptoms and troubleshooting procedures carried out on refrigerators
Symptoms
Refrigerator compressor constantly running, wasting energy and cutting down the life
of the appliance with poor output
Troubleshooting
This could be due to the refrigerator door. When a refrigerator gasket (usually a rubber
seal around the door) becomes hard or cracked, its seal is broken, the unit's efficiency
drops sharply. Test the door gasket for leaks by placing a sheet of paper between the
gasket and the door jamb and closing the door. Pull the sheet out. If it offers some
resistance, chances are the gasket fits properly. If the sheet comes out, the gasket is
faulty and should be replaced. The gasket is tested at different locations around the
door.
Step 2: The new gasket is left for about 24 hours in the room with the refrigerator to
bring it to the correct temperature and humidity, or it is soaked in water to make it
pliable.
Step 3: The old gasket is removed from the door. Door gaskets are held by screws,
clips or adhesives, and the gasket may have a retaining strip, which helps shape it and
provides a fastening tab or guide. On some units, the gasket may be held in place by
the edge of the door panel which is fastened with spring-steel pressure clips, bolts,
screws. To remove the gasket, the fasteners that hold it is removed together with any
retaining strips.
Step 4: After removing the fasteners on one side of the door at a time. Do not remove
the entire door panel. If the gasket is held by spring clips, care must be taken not to pry
too hard on the clips; they are under tension and could spring out of their mountings. If
the gasket is held by adhesive, it is removed with a knife.
Step 5: After removing the gasket, the mounting area is thoroughly cleaned with mild
17
household detergent and water. Stubborn adhesives are removed with mineral spirits
and fine steel wool, followed by a detergent and water rinse.
Step 6: when fixing the new gasket, replacement is begin at one side of the top of the
door, then down to the sides to replace the entire gasket. The gasket is smoothed
evenly into place, easing it around corners. Gasket cement is then use to secure it in
place. During the process the gasket lies flat, with no lumps or curled edges.
Step 7: The fasteners is replaced with the retaining strips, or panel that held the old
gasket in place, the mounting bolts is tightened or loosened to adjust the gasket to the
door jamb.
However, a worn or broken door gasket may not be the cause of your door leaks.
Misaligned and loosed door hinges can cause the door to rock or sag slightly, making
even a well fitted gasket ineffective.
Step 2: If levelling doesn‟t work, tighten the hinge screws. The door will have to be
opened to turn the screws. On some unit, one will have to remove a hinge cap or trim
to teach the screws. Sagging and looseness can be corrected by shimming the door
hinges. The hinge is loosened
Step 3: If the door is warped, tighten the screws that hold the inner door shell to the
outer door shell. You may have to change or adjust the door gasket after making this
adjustment.
Step 4: Check the catch. Newer units have a magnetic catch on the door. If the door
doesn't latch properly, remove the magnetic strike from the inner door shell and shim it
slightly with a piece of thin cardboard. One may have to adjust the gasket to conform
to the new shim.
18
2.7.6 Retubing procedures carried out on a deep freezer
Step 1: Before servicing or recoiling a deep freezer, the main circuit breaker must be
open and all power is off. If the compressor has a capacitor, it must be disconnected
otherwise it may cause a severe shock. The capacitor is located on a housing on top of
the compressor.
Step 2: Opening of the inner silver covering of the freezer and removal of the faulty
tubings.
Step 3:The new copper tube is first joined to one end of the throttling device or
expansion valve; it is then wound round the inside of the compartment, with the use of
a tube bender to bend the copper at the corners.
Step 4: After wounding it round the inside of the compartment, the other end of the
tube is then connected to the compressor.
Step 5: welding of joints such as the one at the throttling device, the compressor and at
19
the connecting point of the copper tubes.
Step 6: the use of soapy and foamy water to check for leakages at the welded points.
Step 7: placing back the silver covering of the inside of the compartment.
20
CHAPTER 3
3.1 INTRODUCTION
Heavy equipment refers to heavy-duty vehicles, specially designed for executing
construction tasks, most frequently ones involving earthwork operations. They are also
known as heavy machines, heavy trucks, construction equipment, engineering
equipment, heavy vehicles, or heavy hydraulics. Of the heavy vehicles available at this
section are the Forklift vehicle and the Tractor.
During my attachment the forklift was rarely used unlike the tractor which ran for an
average of six hours a day, hence, my exposure to tractor than forklift.
3.2 TRACTORS
A tractor is an engineering vehicle specifically designed to deliver a high tractive
effort (or torque) at slow speeds, for the purposes of hauling a trailer or machinery
used in agriculture or construction. Most commonly, the term is used to describe a
farm vehicle that provides the power and traction to mechanize agricultural tasks,
especially (and originally) tillage, but nowadays a great variety of tasks. Agricultural
implements may be towed behind or mounted on the tractor, and the tractor may also
provide a source of power if the implement is mechanized. In the course on my
internship a weed slasher was towed behind the tractors.
I was delegated to carry out routine maintenance of the tractor during my time of
training. Below is an outline of the required checks I was required to carry out on the
tractors:
3. Clean the air cleaner and check the oil level. If it is less, fill it to the required level.
Fill clean oil in case the existing oil has become dirty
21
3.2.2 Weekly (After 50-60 hours of work)
1. Repeat the daily maintenance measure.
2. Check the air pressure in the tyres. If the pressure is low, get the necessary air.
3. Check the elasticity of the fan-belt under the pressure of the thumb. It should stretch
to a degree of 12 & 18 millimeters.
4. Clean the air pressure and fill it with an oil of the right grade.
5. The water stored in the oil filter should be drained out by the drain plug.
6. Check the water-level of the battery. If water is found below the limit, fill it with
distilled water.
8. Apply grease to the clutch shaft and bearings, brake control, bearing of the fan, hub
of the front wheel, tie rod and the radius cross, etc.
4. Change the engine oil. To do so, keep the tractor in starting position for a while and
then switch it off so as to heat up the entire oil, then drain out the oil through the drain
plug and fill fresh and clean oil of the right grade.
5. In case the oil filter is made of paper, element, cloth, felt, etc. change them. Clean
the metallic oil filter.
6. Check the feel play of clutch and brake, it should be 15mm long. Adjust it according
to the need.
22
3.2.4 Monthly (After 250 hours of work)
1. Repeat every step of fortnightly maintenance.
2. If it is advised to clean the primary diesel filter, (in the manual supplied with the
tractor) clean it or change it.
4. Check the water in the battery. If its relative density is below the mark, change the
battery.
3. Get the injector and diesel pump checked either by an authorized dealer or an
experienced mechanic.
2. Drain out the oil of the gear box and fill it with a clean oil of the right grade.
3. Drain out the oil of the back-axle and fill clean oil.
23
3.3 WEED SLASHER
Weed slashers are tractor implements design for grass cutting. Before fitting a slasher
to the tractor, special care has to be taken to make sure the slasher has the same horse
power rating as the tractor. I had to do daily routine check up on the slashers. It should
be noted that our models were all gear driven.
Make sure PTO spring activated locking pin is well greased, sides freely and is
firmly seated in tractor PTO splined angular groove.
Lubricate all grease fitting locations. Make sure PTO joints and shaft are well
lubricated
Remove small oil level plug on side of gearbox and assure oil leaks out. Top up
if no oil is present.
Check blades are sharp and secure and cutting edge is positioned to lead when
rotating anticlockwise.
Check that all shields and guards are properly installed and in good condition
Check cutting height, front to rear attitude and top link adjustment.
Ensure tractor PTO and transmissions are in neutral before starting engine.
24
Figure 9. Weed Slasher
Waiting in traffic with the vehicle in Gear and Clutch disengaged is a major
contributing factor, this loads the clutch release bearing excessively and
shortens both the bearing and clutch assembly life drastically. Bad driving
habits such as resting the foot on the clutch pedal while driving the vehicle is
also one of the major causes of premature clutch failure.
If the seat is too far back as many drivers prefer, the clutch pedal is often
insufficiently depressed during gear changes and clutch disengagement
problems can occur. Also drivers do tend to rest their foot on the clutch pedal
which induces excessive bearing wear.
25
If the seat is too close to the driving position conversely, the clutch pedal can
be over stroked which also causes release/engagement problems and premature
clutch failure.
Symptoms
2. We disconnected the clutch release rod from the release arm by removing the
split pin and clevis pin.
3. We then lifted the inner end of the return spring away from the clutch fork,
rotate the fork and withdraw the release bearing and hub assembly.
26
5. We fitted the new release bearing, ensuring that the thrust face is facing
outwards.
6. We packed the recess in the release hub bore with an extreme pressure high
melting point grease.
7. We then slided the release bearing and hub assembly into position whilst
engaging the fork with the slotted arms of the hub.
8. We then rotated the fork to the rear and, with the hooked end of the return
spring located around the lug cast in the housing and engaged the inner end of
the spring with the front face of the small projection on the side of the fork.
Figure 11. A tractor after being separated for clutch bearing replacement
27
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.
Alternator
Fuel System
Voltage Regulator
Cooling System
Exhaust System
Lubrication System
Engine
The engine is the source of the input mechanical energy to the generator. The size
of the engine is directly proportional to the maximum power output the generator
can supply. There are several factors that you need to keep in mind while assessing
the engine of your generator. The manufacturer of the engine should be consulted
to obtain full engine operation specifications and maintenance schedules.
Alternator
The alternator, also known as the „genhead‟, is the part of the generator that
produces the electrical output from the mechanical input supplied by the engine. It
contains an assembly of stationary and moving parts encased in a housing. The
28
components work together to cause relative movement between the magnetic and
electric fields, which in turn generates electricity.
Fuel system
The fuel tank usually has sufficient capacity to keep the generator operational for 6
to 8 hours on an average. In the case of small generator units, the fuel tank is a part
of the generator‟s skid base or is mounted on top of the generator frame. For
commercial applications, it may be necessary to erect and install an external fuel
tank.
Voltage Regulator
As the name implies, this component regulates the output voltage of the generator.
The mechanism is described below against each component that plays a part in the
cyclical process of voltage regulation.
29
windings now function similar to the primary stator windings and generate a
small AC current. The exciter windings are connected to units known as
rotating rectifiers.
This cycle continues till the generator begins to produce output voltage equivalent
to its full operating capacity. As the output of the generator increases, the voltage
regulator produces less DC current. Once the generator reaches full operating
capacity, the voltage regulator attains a state of equilibrium and produces just
enough DC current to maintain the generator‟s output at full operating level.
When you add a load to a generator, its output voltage dips a little. This prompts
the voltage regulator into action and the above cycle begins. The cycle continues
till the generator output ramps up to its original full operating capacity.
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
30
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. The generator should be placed in an open and ventilated area that has
adequate supply of fresh air. The National Electric Code (NEC) mandates that a
minimum space of 3 feet should be allowed on all sides of the generator to ensure
free flow of cooling air.
Exhaust System
Exhaust fumes emitted by a generator are just like exhaust from any other diesel or
gasoline engine and contain highly toxic chemicals that need to be properly
managed. Hence, it is essential to install an adequate exhaust system to dispose of
the exhaust gases. This point cannot be emphasized enough as carbon monoxide
poisoning remains one of the most common causes for death in post hurricane
affected areas because people tend to not even think about it until it‟s too late.
Exhaust pipes are usually made of cast iron, wrought iron, or steel. These need to
be freestanding and should not be supported by the engine of the generator.
Exhaust pipes are usually attached to the engine using flexible connectors to
minimize vibrations and prevent damage to the generator‟s exhaust system. The
exhaust pipe terminates outdoors and leads away from doors, windows and other
openings to the house or building. You must ensure that the exhaust system of your
generator is not connected to that of any other equipment. You should also consult
the local city ordinances to determine whether your generator operation will need
to obtain an approval from the local authorities to ensure you are conforming to
local laws and protect against fines and other penalties.
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
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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.
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CHAPTER 4
4.1 INTRODUCTION
The Student Industrial Work Experience Scheme (SIWES) has been of great help in
assisting me correlate the theoretical parts of Mechanical Engineering to the practical.
My exposure to maintenance engineering has brought to fore the fact that unnecessary
breakdown can be prevented and by extension money saved. Indeed, survival of an
organization could lie solely with the Engineer.
These work experience has also built my self confidence in approaching problems.
c. Maintenance of Tractors.
The knowledge of installation is also vital in the engineering circle in Nigeria. The
existence of industries means the relevance of maintenance.
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CHAPTER 5
5.2 RECOMMENDATIONS
Below are my recommendations for a better SIWES program:
a. The employers and universities should develop better ties to facilitate prompt
placement of students.
c. To the interns, I would posit that the craftsmen and the technicians should not
be looked down upon as there is a lot to gain from them.
5.3 CONCLUSION
The student industrial work experience scheme has been a good experience. The
training I got during the program has made me a better engineering student and will
make me a better engineer in the future.
The program did not just affect my academics positively by giving me a clearer picture
of what engineering is. It also has made me more disciplined and has taught me how to
relate professionally with other people.
34
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Williams Wangka Jikisim, logbook 2014/2015
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