Sampson Tubonimi Report

7/30/2019 Sampson Tubonimi Report

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CHAPTER ONE

1.1 BACKGROUND INFORMATION

The student industrial work experience scheme (SIWES) was established by the

industrial training fund (IT) in 1973 to solve the problem of lack of adequate

practical skills preparatory for employment in industries by Nigerian graduates

of tertiary institution.

The student industrial work experience scheme students to improve and

industrial based skills. It is an imperative need for every Nigerian students to

achieve a smooth transition from classroom practice to the word competitive

work. It also affords students of tertiary institutions the opportunity to

familiarize and expose themselves of handling machinery and equipment which

are usually not available in the equational institutions.

Students industrial work experience scheme (SIWES) has become a necessary

pre-condition, for a student to participate before they are awarded a diploma and

degree certificates in specific disciplines in institutions of higher learning in

Nigeria, in accordance with education policy of the government.

An industrial training experience within the exploration and production

organization such as JOVETEC has exposed me to leading technology tool in

the area of production, HSSE and provided me with practical skills required forworking in the industry. The work experience have guided me to use practical

applications and broaden my knowledge in most of the theoretical concepts, I

learnt in the classroom over the years of my tertiary education at the Rivers

State University of Science and technology Nkpolu Port Harcourt Rivers State.

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1.2 ABOUT JOVETEC CONST./ENGR. COMPANY

The JOVETEC CONST./ENGR. COMPANY is one of the most promising

Engineering Company in Nigeria. It exploits in various areas of engineering

disciplines especially in production engineering. It also has its link expanded

towards oil and gas sectors.

Jovetec Const./Engr. Companys operations are servicing of Heavy Duty

Engines such as G3306 Engines, overhauling of engines of various types and

dimensions.

The company employs more than 1,000 staff. Ninety five percent of whom are

Nigerians. In addition, more than 20 people are employed by contractors

working for JOVETEC and projects that creates opportunities for tens of

thousands more jobs with contractors in supporting industries.

JOVETEC is committed to sustainable development and therefore supports

developments and progress within communities in areas of operations. Theoverall goal of our social investments programmes is to leverage the resources

and empower local communities to take lead in their development process.

Above all, JOVETEC Const./Engr. Company believes in the future of the

country and the company is committed to its development.

1.2.1 MISSION OF JOVETEC

The mission of JOVETEC is to be the operator of first choice in Nigeria through

its commitments to strong economic performance and to every aspect of

sustainable development.

1.2.2 VISION OF JOVETEC

To become the industry leader, employers of first choice and a company that

delivers as promised.

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1.2.3 HISTORICAL BACKGROUND OF JOVETEC

JOVETEC CONST./ENGR. COMPANY started business in Nigeria 1990. It

was initiated by a man called ENGR. JOHNSON AGWU and with a total of 50

staff in 1990. Due to their effective and efficient method of

production/servicing, there has been an increase in their organizational

structure/increase in organizational goals.

1.2.4 GEOGRAPHICAL LOCATION OF JOVETEC

JOVETEC CONST./ENGR. COMPANY is located at 238 Aba-Port Harcourt

Express Road Aba, Abia State.

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CHAPTER TWO

2.1 INTRODUCTION TO MECHANICAL WORKSHOP AND

EQUIPMENTS

Mechanical workshop is a mechanical maintenance department in JOVETEC

CONST./ENGR. COMPANY which is based on trouble shooting and

overhauling of caterpillar engines and crude oil pumps of different models.

Mechanical maintenance workshop is further divided into different sections

such as engine bay, accessories section, cylinder head section, Clutch section,

radiator section, pump section etc.

2.2 ENGINE BAY

An engine is a power unit that operates either in four strokes or two strokes

cycles that drive rotating equipments such as pumps and alternators etc.

In this bay we worked on different model of caterpillar engines such as G3304,G3306, D3304, D3306, G342, G3408, G3412 D3408, D3412, G3508, G3512,

D3508, D3512 and D3516 etc.

Before ever we repair or overhaul an engine, we first of all trouble shoot to

know the fault of that engine. If it is a fault that affects the internal part of the

engine, that means, the engine will undergo complete overhaul. Meaning strip

down of the engine and change the parts that are faulty.

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G342 CATERPILLAR ENGINE SET

2.2.1 COMPONENTS PARTS OF AN ENGINE AND THEIR

FUNCTION

2.2.1.1 PISTONS

This is a component part of an engine that helps to increase the temperature and

pressure of the air fuel mixture in the combustion chamber for combustion to

take place easily.

2.2.1.2 CONNECTING ROD

This is the rod that connects the piston to the crankshaft of an engine.

2.2.1.3 GUDGEON PIN

This is a pin that holds the connecting ROD firmly to the piston.

2.2.1.4 LINNERS OR CYLINDERS

It is just like a slip or cylinder in which the piston is fit in.

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2.2.1.5 CRANKSHAFT

This is the power house of an engine. It converts the reciprocating motion of the

connecting rod to a rotary motion.

2.2.1.6 BEARING

It helps in reducing friction in rotating parts of the engine.

2.2.1.7 OIL PUMP

It pumps the oil from the oil sump to the lubricating parts of an engine.

2.2.1.8 OIL FILTER

This is a component that fitter the oil before the oil pump pumps the oil to the

lubricating parts.

2.2.1.9 FUEL FILTER

It filters the fuel before getting into the engine.

2.2.1.10 OIL COOLER

This is part of engine that cools the heated oil before getting back to sump. Its

construction is of tube and shell. The water that cools the oil passes through the

tube while the heated oil passes through the shell.

2.2.1.11 WATER PUMPIt pumps water from the radiator and send it to the water jacket in the engine

block.

2.2.1.12 CAMSHAFT

This is a part that is linked to the crankshaft that pushes cam followers, then the

followers pushes the push rod and pushes the rocker arm assembly for the

opening and closing of values.

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2.2.1.13 OIL BAFFLE

It is a seal that seal the crankshaft of the engine so that there will be no oil

leakage from that end.

2.2.1.14 FAN BLADE

It blows out the heat through the core of the radiator.

2.2.1.15 FAN DRIVE

This part is linked to the crankshaft with the aid of belt which drives the fan

blade.

2.2.1.16 RADIATOR

It cools down the hot water that comes out from the engine to a required

temperature before sending it back to the engine with the aid of a water pump.

2.2.1.17 GOVERNOR

It regulates the speed of an engine, when it is loaded, it will increase or reduce

the speed by opening and closing of the butterfly valve in the carburetor.

2.2.1.18 THARMOSTAT

This is the part of an engine that regulates the temperature of an engine. When

the water in the engine is hot the thermostat will open itself for the hot water to

get into the radiator.

2.2.1.19 MAGNETO

This is the part of the engine that generates current in the engine, but the current

it produces is very small.

2.2.1.20 IGNITION COIL

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This part increases the low current that is being produced by the magneto to a

high current that can ignite the engine.

2.2.1.21 SPARK PLUG

This produce spark that can ignite the air fuel mixture in the combustion

chamber.

2.2.1.22 INDUCTION PUMP

It pumps dieseline into the engine.

2.2.1.23 NUZZLE

It is a component that gives fine spray of the fuel into the combustion chamber.

2.2.1.24 FUEL LINE

It is the line in which fuel from the induction pump is being transferred to the

NUZZLE.

2.2.1.25 RADIATOR PRESSURE CAP

This is the cover of the top tank of the radiator.

2.2.1.26 TURBOR-CHARGER

This is the part that increases the efficiency of the engine and it is always

located at the exhaust pipe.

2.2.1.27 AIR CLEANER

It is the component that filters the aim that goes into the engine.

2.2.1.28 AFTER COOLER

After cooler cools the air that get into the engine.

2.2.1.29 AUXILIARY WATER PUMP

This pumps water to the supercharger of the engine.

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2.2.1.30 GAS REGULATOR

It regulates the amount of gas that goes into the engine.

2.2.1.31 CARBURATOR

It mixes the gas that comes from the gas regulator and the air that comes from

air cleaner to the required ratio and sends it to the engine according to the firing

order of the engine.

2.2.1.32 STARTER MOTOR

Its function is to crank the engine. There are two types, the electrical type

known as kick starter and the mechanical type known as air starter.

The electrical type makes use of motor battery while the mechanical type makes

use of air.

2.2.1.33 PULLEY AND DAMPER

It is the component part of an engine that absorb the vibration that is being

caused by the crankshaft in the engine and it also transfer the rotating motion ofthe crankshaft to the far drive with the aid of the fan belt.

2.2.1.34 BREEDER

Its function is to expel the vaporized gas that comes out from down the sump

apart from the combustion chamber.

2.2.1.35 SERVICE METER

This is to indicate weather the engine has riched the period of service.

2.2.1.36 SUPPER CHARGER

This performs the same work as the turbo charger but can be differentiated with

their power drives. The turbo charger gets its power drive from the exhaust

stream while the supper charger gets its powers drive from the crankshaft and it

is connected to the crankshaft with the aid of belt.

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2.2.1.37 FERULES

It protects the water that comes out from the cylinder head via water galleries

not to get into the engine.

2.2.1.38 ACTUATOR

This regulates the speed of the engine, it collects signal from the electronic

governor.

2.2.2 STRID DOWN OF AN ENGINE

This simply means decoupling or disassembling of all the component parts of an

engine. As I stated earlier, we worked on different model of caterpillar engine

but let me use G342 as a case study.

Start by draining the oil in the sump and the water in the radiator. After then

commence disassembly and keep nuts, bolts, washers, studs etc belonging to the

equipment together. Ensure proper separation of parts.

Decouple accessories like fan drive, starter motor, water pump,

carburetor, radiator etc and send to accessories section with job order.

Carry out thorough inspection of the accessories and ensure that they are

in good condition, otherwise overhaul using genuine parts and carry out

the appropriate test where necessary.

Remove valve covers/valve mechanism, carefully unbolt and remove

cylinder heads and sand to the cylinder head section with job order for

overhaul and pressure testing.

Turn engine over on inspection stand and remove sump, connecting rods,

pistons crankshafts, journal bearing, timing gears etc.

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Extract engine liners

Scrape off mating surfaces of the engine block and other parts to remove

remains of old gaskets.

Wash parts in suitable solvent to dissolve oil dirts and rusty scales,

steam clean all stripped parts.

Polish all the mating surfaces with emery cloth.

Carry out dimensional test on major components (e.g crankshaft; liners,

pistons etc) and confirm any deviations from standard values based on

OEM specification in particular crankshaft straightness check and wear

should be eared out.

After detailed inspection and all necessary measurement, prepare a strip

down report showing the list of reasonable and non reasonable parts.

Generate scrap report and parts to the yard.

Generate list of a new spares required to augment the reusable parts and

seek for approval from the appropriate authority.

2.2.3 BUILDING OF AN ENGINE (G342)

This means putting all the components parts of an engine back to its normal

fitting position. This can be done by introducing the following steps.

Use compressed air to blow all the galleries in the engine block.

Installation Of Liners: Put the liners seal on the liners and then press

the liners in the liners chamber with the liner installer.

Installation of Crankshaft: Ensure that the female part of the journal

bearing is fit on the engine block and the male part on the cap of the

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journal, then place the crankshaft on crankshaft end of the engine block

and the with aid of plastiguage determine the clearance of the crankshaft

and the bearing and ensure that it falls within the range prescribed. Then

guard the bolt and torque according to manufacturer specification.

Ensure that the bearings are placed key to key. Journal torque wretch

value for G342 is 3501bF. Plastiguage measurement for G342 journal

0.006.

Installation of Pistons: Ensure that the pistons wrings are fixed on the

pistons accordingly as oil ring, scraper ring and compression ring. The

rings should also be positioned in different angle. Also mount the

connecting rod on the piston and carefully fix the piston on the engine

block with the aid of piston installer. Also ensure that clearance is

checked, then guard the bolts and tighten according to manufacturer

specification. The torque wrentch value is 190IbF while that of the

plastic gauge measurement for connecting rod is 0.003.

Mounting of Camshaft: Ensure that timing mark of the crankshaft align

with the timing mark of the camshaft. The timing mark of some engines

are always symbolized as C while others are always symbolized as

V.

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Mounting of Magneto Drive: Be ensured that the timing mark of the

magneto drive align with the timing mark of the crankshaft.

Mounting of Timing Cover: Ensure that the timing cover gasket is well

placed before tightening to avoid leakages.

Mounting of Oil Sump: First of all mount the oil pump on the sump

then place the oil sump gasket on the engine block and ensure that it

does not shift from its fitting position then lift the oil sump with the aid

of crane and belt to be placed on the engine block and guard the bolts

and tighten.

Mounting of Flywheel Housing: Lift the flywheel housing with the aid

of crane and belt place it on the end of the engine block, then guard the

bolt and tight it according to the manufacturer specification and the

torque wretch valve is 150IbF.

Mount the front engine leg and turn the engine with the aid of crane and

belt.

Mounting of Cylinder Head: Place ferrules and top cylinder head

gasket on the engine block then lift the cylinder head with the aid of

crane and belt, use compressed air to blow the cylinder head and place it

on the engine. Ensure that the cylinder head is well lapped before

guarding the bolt and tighten according to manufacturer specification.

The cylinder head have two sets of bolt, one is small while the other one

is big. The torque wrench value of the smaller both is 190Ibf while the

torque wrench value of the bigger bolt is 350Ibf.

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Mounting of Oil Throughwer: Ensure that it is heated to about 900c for an

expansion before putting it on the flywheel view of the crankshaft.

Mounting of oil baffle

Mounting of Flywheel: Ensure that the timing mark of the flywheel is

align with that of the crankshaft. Also ensure that it is torque according

to manufacturer specification and the torque wrench value is 2016f.

Mounting of oil cooler, oil filter base, breeder, exhaust manifold and

inlet manifold.

Mounting of Pulley and Damper: Lift the pulley and damper with aid

of crane and belt place it on the front end of the engine then guard the

bolts and torque according to manufacturer specification. The torque

wrench value is 600Ibf.

Mounting of accessories of a engine such as water manifold, air state,

water host, fan drive, fan belt, gas regulator, butterfly value and

carburetor.

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Mounting of Magneto: Ensure that the flywheel rotates to about 250

after TDC of 1 and 6 before mounting the magneto so that it will be on

accurate timing.

Connection of Magneto to the Ignition Coils: Ensure that the wires are

connected to the ignition coil according to the alphabet and the firing

order of the engine (1 5 3 6 2 4). The numerical order indicates the

cylinders.

A - Ignition coil 1

B - Ignition coil 5

C - Ignition coil 3

D - Ignition coil 6

E - Ignition coil 2

F - Ignition coil 4

Mounting of valve Mechanism: Ensure that the push rod are place on

their fitting position before mounting the value mechanism.

Valve Setting: The valves are set according to manufacturer

specification. In valve setting turn the engine first revolution set the

valves and turn it to second revolution set again. Revolution means turn

the crankshaft of engine to 3600.

First Revolution Inlet 1 Inlet 2 Inlet 4

Exhaust 2 Exhaust 3 Exhaust 5

Second Revolution Inlet 6 Inlet 5 Inlet 3

Exhaust 6 Exhaust 4 Exhaust 2

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Mounting of Governor, air cleaner housing, radiator, exhaust elbow,

spark plugs, mofil panel, and mounting magneto pig up on the flywheel

housing.

When building of engine is completed, fill radiator with water and allow

for about 24 hours under atmospheric pressure, chock for leakage. If

water level remain the same, than fill engine sump with appropriate oil.

Carry out primary test run, adjust all the necessary parts accordingly.

G342 Engine being connected to Emsco pump.

2.3 CLUTCH SECTION

Clutch is a take off device that engages and disengages the motion of an engine

to pump for the purpose of pumping crude oil via belt and pulley connection.

Basically there are three types of clutch which are automatic or hydraulic clutch

that is operated with flutch.

Manually operated two plate clutch

Manually operated three plate clutch

2.3.1 COMPONENTS PARTS OF CLUTCH

Hub Assembly: It is made of hub, fiber plate, center friertional plate,

top plates, adjustment nut, lings, stopper spring.

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Shaft Assembly: It is made up the shaft itself, cone bearing, cups, cir

click, carrier, carrier lock nut, stopper bolt.

Sleave Assembly: It comprises the sleave, twin disc or coller, clutchfingers, host, cutter pin.

Leaver Assembly: It is made up of the clutch handle, the side shaft and

the yoke.

Clutch housing

2.3.2 STRIP DOWN OF TWO CLUTCH PLATE

The strip down procedure is as follows:

Remove all attach parts from the output end of the PTO shaft. Remove

the key from the shaft. Drain oil from sump of PTO. Remove dip stick

from housing. Removing support plate if used.

Remove the hex-head cap screws that came the PTO housing to the

flywheel housing. Remove the power take off from the engine.

Remove the hex-head cap screws that secure the drilling ring to the

engine flywheel. Remove the driving ring.

Set the power take off on a work bench supported by wood blocks with

the input and facing up.

Straighten the portions of lock plate which were bent against flats of the

heads of three hex-head cap screws, and remove the cap screws lock

plate and retainer washer from the end of the drive shaft.

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Use conventional gear puller and remove the spider and key from the

PTO shaft. Remove the rubber blocks from the spider only if

replacement of the parts is necessary.

Remove the six hex-head cap screws which secure the bearing support

carrier to the PTO housing, and remove the bearing carrier from the

housing using 3/8-16 pusher cap screws in the holes provided 180 0 apart

in the carrier. Remove seal ring from the housing.

Remove the internal snap ring which retains the roller bearing outer race

assembly in the bearing carrier. Remove the bearing and oil seal from

carrier. Tap seal forward and bearing rearward to remove.

Use a conventional bearing puller and remove the bearing inner race

from PTO shaft, pulling forward off of the input end of the shaft.

Remove the six hex-head cap screws which secure the bearing retainer

and shims to the PTO housing. Remove the retainer and shims from the

housing.

Attach a hoist with an eyebolt to the input and of the PTO shaft and lift

the shaft from the housing. You may have to tap the housing to unseat

forward bearing cup.

Remove the bearing cones and cup from the shaft, using a press or

conventional bearing puller.

Tap the oil seal from the housing.

Remove the two bearing cup access plays and with a long narrow shark

punch, tap out the rear bearing cup.

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Remove the four drive screws and remove the specification plate only it

replacement of the parts is necessary.

2.3.3 BUILDING OF TWO CLUTCH PLATE

Bearing inner races and/or cones, shift mounted, may be heated to not over

3000F in an oven or oil bath to facilitate assembly.

Install the specification plates securing it to the housing with four drive

screws if the plate was removed previously.

Install the pipe plug into the PTO housing and tighten securely.

Install the oil drain, oil plug and tighten seemly to 35-47Ibft torque.

Install the tapered roller bearing cup use a piece of steel tubing slightly

smaller than in O.D than the O.D of the bearing cup and about fifteen

inches long and squarely tap the bearing cup into its bore from front

toward rear with the cup back face (wide section) bottoming at the rear

of the bore. Install the two plugs in the holes at the rear of the housing

and tighten the plugs securely 7--1016s.ft torque.

Install the oil seal in its bore at the rear of the PTO housing press or tap

the seal securely into the bore until the steel casement is flush with the

rear surface adjacent to the bore. The dust lip section of the seal should

be at the rear prelubricate the seal with engine oil.

Press the two bearing cokes onto the PTO shaft so their back faces butt

against the collar machined on the shaft for the purpose.

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Press the inner bearing race onto the PTO shaft from the front securely

press the bearing race to but against the shoulder provided on the PTO

shaft, pre-lubricate the bearing race.

Set the PTO housing on a work bench supported with wooden blocks, so

the input end faces upward. Install the PTO shaft with attached parts into

the housing. Be careful, when entering the PTO shaft in the rear oil seal,

so damage of the seal is prevented.

Install the front bearing cup in its bore and press or tap it against the

bearing cone and squarely press the cup into position.

To select a shim park, of usually two shims to establish bearing free

play, proceed as follows.

a. Install the bearing retainer and secure it to the PTO housing with six hex-

head cap screws. Tighten the cap screws to a point where the bearing free

play is eliminated. Rotates the shaft several times and seat and align the

rollers. Use a set of filler gauges and measure the gap (shim) distance

between the bearing retainer and the PTO housing. Add 0.006-inch to this

measurement for bearing free play and select two shims which will

provide this thickness. Remove the six cap screws and bearing retainer

from the PTO housing.

b. Install the selected shim pack over the shaft and onto the bearing retainer

mounting surface on the PTO housing.

c. Install the bearing retainer and secure it to the PTO housing on top of the

shim pack with six hex-head cap screws. Tighten the cap screws to 38-

42Ibs-ft torque.

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d. Attach a dial indicator to the PTO housing. So the indicator plunger or

stem rests on the end of the PTO shaft, (Input end). Raise the PTO shaft

with a hoist to move the forward bearing cup against the bearing retainer.

You may have to tap the PTO housing downward.

e. Zero the dial indicator with the hoist released pick up the shaft with the

hoist. Rotate the shaft several times to seat and align the rollers. Note the

dial indicator reading from zero. Lower the shaft indicator should be zero.

The noted reading should be 0.006-0.010inch for proper bearing

adjustment.

Press the outer roller bearing race squarely into its bore of the bearing

carrier. The bearing race assembly is installed from the rear toward the

bottom in the bore. Press on the outer race of the bearing only. Install the

internal snap ring in its groove adjacent to the bearing to secure the

bearing in the carrier.

Press the oil seal into the carrier from the front the dust lip must be

forward and the steel seal casement must be flush with the front surface

around the bore.

Install the rubber oil seal on the pilot of the bearing carrier pre-lubricate

the oil seals position the bearing carrier with attach parts into the PTO

housing and secure it to the housing with six hex-head cap screws.Tighten the cap screw to 38-421bs.ft torque.

Install the spider key into the PTO shaft and install the spider onto the

shaft. Secure the spider to the shaft with a retainer washer, a lock plate,

three hex-head cap screw. Tighten the cap screw to 177-195Ibs.ft torque

upset the look plate tabs against the flats of the screw.

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Install new rubber blocks and required.

Install the driving ring on the engine flywheel.

Install the breather pipe into the PTO housing if removed. Install the

breathe and oil level gauges onto the breather pipe.

Swing the PTO assembly into position on the engine flywheel housing,

carefully, meshing the drive spider rubber blocks with the internal teeth

of the driving ring. Then secure the PTO housing to the flywheel

housing.

Install the support plate

Fill the unit with oil to full mark

Install key in PTO shaft, and attach all parts previously removed from

output shaft.

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CHAPTER THREE

3.1 MAINTENANCE OF INNER MECHANISM

This is a mechanism inside a positive displacement meter (PD meter) that is

involved in flow measurement. Is the qualification of bulk fluid movements it

accumulate a fixed times the volume is filled to measure flow. Flow can be

measured by measuring the velocity of fluid over a known area.

3.1.1 PRINCIPLES OF OPERATION

The A.O Smith meter is of the rotary positive displacement type. The accurately

machined housing contains a rotor which revolves on ball bearings and carriers

evenly spaced blades. As liquid flow through the meter, the rotor and blades

revolve about a fixed cam, causing the blades to move outward. The successive

movement of the blades forms a measuring chamber of precise volume between

two of the blades, the rotor, the housing the bottom and top covers. A continues

series of these closed chambers is produced for each rotor revolution. Neither

blades nor rotor contact the stationary walls of the measuring chamber.

One of the outstanding features of this meter principle, the flow is literally

undisturbed while it is being metered. Energy is not wasted by arresting liquid

velocity; consequently high accuracy and efficiency are common place with the

mater.

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FLOW STATION SHOWING PD METER

3.1.2 DISASSEMBLY OF INNER MECHANISM

The inner mechanism removal and disassembly procedures are as follows:

Take out the bolts that fasten the body to the housing.

Using the lifting hugs, remove the inner mechanism from the housing.

Take out all the cover screws, place cover screws into the tapped holes

using the screws as jack, remove the cover.

During disassembly of the inner mechanism, clearance may be checked

to determine the condition of the various parts. To be done accurately, a

spider should be used. The fixtures maintain inner housing

concentrically when the cover is removed.

Take out the machine screws and plate located on the underside housing;

remove the rotor from the housing. Lift out carefully to prevent

damaging the blades.

To disassembly the rotor, place the assembly upside down on a suitable

surface, loosen the socket head cap screw and lift off locating arm.

Remove the screws and clamps that secure the rollers to the rotor.

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Lift out the rollers and pins check for wear and smoothness of operation.

To separate the cover and rotor, pry up at the openings provided.

Lift off the cover

Remove the lower rotor bearing if it is still in place.

Lift shaft assembly, and take out the upper blade.

Turn the rotor over and remove the rotor gear plate.

Take out the screws that hold the plate to the rotor and lift off. Remove

the upper rotor bearing, spacer, and thrust bearing, if necessary, drivewith punch made of soft materials.

To disassembly shaft and cam, place shaft in press or vice to compress

spring so that pin cam be removed from the color.

The can may be removed from the shaft by pressing it off. A woodruff

key is used to prevent the cam from turning on the shaft.

The adjusting screw extension pin is removed from the shaft by taking

out the adjusting screw nut and washer.

Remove cotter pin and press out blade roller pin with a drill rod.

3. 1. 3ASSEMBLY OF INNER MECHANISM

Reassembly is essentially the reverse of the disassembly procedure.

Be sure to observe the reassembly precautions noted during teardown of the

unit.

1. Should it become necessary to install a new rotor assembly into a meter,

check rotor to blade clearances, refer to clearance check section.

If clearances are too small, block should be removed and the necessary

clearances provided by filing metal from the back of the block.

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If clearances are too great, the block should be shimmed to provide

proper clearances.

Dress all rotor all edges lightly with file to remove any burs.

2. New blades installed into a rotor must be fitted to the motor case.

Position any two adjacent blades to their furthest extension position.

Raise the assembly to a position over the inner limit.

Line up rotor so that extended blades are just inside of the indentations

in the case at either end of the measuring chamber.

Slowing, lower rotor assembly into position in the inner housing.

By means of adjusting screws, lower rotor until it bottoms, it spider is

used there should be some clearance between the rotor and base.

Care must be taken when installing the inner unit cover to assure that the

rotor gear and the lower jackshaft gear are properly meshed.

Total end clearances is divided, top and bottoms by setting the rotor

adjusting screw.

Loosen the adjusting screw lock nut and while turning the rotor, slowly

raise the rotor assembly until it just begins to bind against the top cover.

With the rotor in this position, check the bottom rotor clearances at both

the inlet and outlet ports compare with clearance guide.

By means of adjusting screw lower rotor until 1/3 of this clearance is at

the tip and 2/3 is at the bottom.

Add 0.002 0.004 to the top clearances to allow for the frightening of

the lock nut.

Tighter adjusting shaft lock nut and check top and bottom rotor

clearances to see that they are 1/3 off the top and 2/3 off the bottom.

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If these clearance do not check, loosen lock nut and repeat the complete

adjusting procedure.

After this adjustment has been satisfactorily completed, and lock nut

tightened, record this measurement as as assembled clearances.

5. Determine rotor to block and blade slot clearances.

6. Assemble inner unit into outer housing.

Clean the machined surfaces of the outlet port of the inner unit and outer

housing with alcohol or solvent.

Coat both surfaces with loctite master gasket or other sealing medium.

Lower inner unit into outer housing. Apply Vaseline or petroleum jelly

to the o-rings on the cap screws and installing washers, draw inner unit

up to seal outlet port.

7. Complete Reassembly

Coat p-ring with Vaseline or petroleum jelly and install o-ring in groovein top of outer housing.

Install cover. Be sure to line up locating pin in cover with hole in

housing flange.

Install all remaining parts and accessories.

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CHAPTER FOUR

4.1 CONCLUSION AND RECOMMENDATION

As stated earlier the contemporary relevance of the SIWES program can not be

over emphasized, and its benefits are much more numerous.

Every student who truly and fully participated in the SIWES industrial

attachment can testify to this facts.

4.1.1 PROBLEMS ENCOUNTERED (SIWES)

Although I have a wonderful time during the program, whose memory will

remain indelible in my sense of reminiscence. Nevertheless, I was also

confronted by some short comings related to safety and other industrial

problems. Actually at my work resumption day I was made to understand safety

rules.

1. Industrial Problems (Safety Equipments)

Incomplete issuance of personal protective equipments. At the

commencement of the training program, I was not given a complete PPE;

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such as Helmet, hand gloves and safety booth; this actually affected my

performance effectiveness at the very beginning of the training.

2. Supervisors Attitude

The attitude of some supervisors working with me was not so encouraging,

especially in sections like flow station and Gas plant etc. as they do not allow

the tools to be carried out directly or personally by me and some assisted me in

answering most of the difficult questions I could not answer whereas others are

not ready to give

any assistance on the work done.

3. Health Problem

This is an important aspect of the human life. In JOVETEC site and

surroundings are heavily polluted by some chemical waste products,

which are most considerably harmful to the human health.

4. NOISE POLLUTION

Noise pollution in JOVETEC is so intense that it should be looked into

properly. I observed that audiometric test is only done on the staff. The

contract staff and those on industrial attachment are not considered.

Supervisors and guidan

e from SIWES board and institutions should be sent as much as possible

to industries to properly direct, observe and instruct the participants were

necessary and student should be more enlightened before going for their

attachment.

I strongly appeal to the SIWES board/ ITF to ensured that every

institution attached importance to this program as well as attaching a

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credit unit, so that students can take it very serious as part of their course

work.

This phenomenon has become imminent considering that throughout mysix months stay in JOVETEC no supervisor, either from the SIWES

board or my department came see how we are coping.

4.1.2 WAYS OF IMPROVING THE PROGRAMME

Besides its relevance the SIWES program also has its short comings, most of

which can be over looked.

i. The SIWES can be made more efficient by increasing training

opportunities for the students, so that the goals and objectives could be

achieved satisfactorily.

ii. The necessarily working place should be provided for student by the

SIWES board, since most students are restricted in mobility due to

finance, to actually find a reputable place for themselves.

iii. Strengthening its requisite power capability to enable the companies or

firms to employ many students as possible, this can uplift the program

drastically.

iv. The industrial training fund (ITF) should increase the allowance paid at

the end of the program to enable student who are willing and ready to do

the program.

4. 1.3 ADVICE TO FUTURE PARTICIPANTS

Having fully participated in the SIWES Programme, i would humbly advice

future participants to firstly believe in God for a placement and make sure that

they take the programme with absolute diligence to enable them acquire

practical skills which are not easily obtainable in higher institutions of learning

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and they should also be punctual and show full commitment to their appropriate

duties, bearing in mind that this opportunity might never be given to them again

and finally they should be honest, transparent and hardworking. Above all they

should put up a positive mental attitude.

4.1.4 ADVICE TO THE SIWES MANAGERS

My advice to SIWES Managers is to try as much as possible to maintain the

continuity of the program. This is because of the fact that it helps student in

having the technical- know-how of their respective discipline.

Finally, I which to let them know that in spite of all their short comings, they

are still doing a good job by bridging the gap, which had been a barrier to our

educational structure.

4.1.5 CONCLUSION

Above all, it could be deduced that the program will go along way in generating

a pull of indigenous trained labor force, sufficient to meet the needs of the

economy. If the above views are taken into consideration. Thus, I see industrial

training as a very important part of the university training and its inclusion in

the curriculum is justified.

4.2 RECOMMENDATIONS

I wish to recommend on the following area which can necessitate the programto a higher level.

i. Students should be given instructors or supervisors from the university to

properly monitor the training.

ii. The University (RSUST) in Particular should attach a grade unit for the

industrial training; thus this will aid to taken the program seriously.

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iii. Industries should see that students within their jurisdiction are well

trained.

iv. Authorities concerned should ensure that allowance are paid shortly as

when due to be paid.

v. I also recommend the company I worked with, as place of attachment for

students.

REFERENCES

R.T. Pritchard, 1965, T3 Workshop Technology for Mechanical

Engineering and Technicians; S.I. Edition.

W.A.J. Chapman, 1946, Workshop Technology Part 2, Fourth Edition.

Port Harcourt Refining Company Limited Brochure. (2005 Edition).

PHRC C2

Documents

Sampson Tubonimi Report