CHAPTER ONE
STUDENTS INDUSTRIAL WORK EXPERIENCE SCHEME (SIWES)
1.0 INTRODUCTION TO SIWES
The Students Industrial Work Experience Scheme (SIWES) was established by the Federal
Government of Nigeria in 1973 and is jointly coordinated by the Industrial Training Fund (ITF)
and the National Universities Commission (NUC). It is the accepted skills training programme,
which forms part of the approved minimum academic standard in the various degree
programmes for all the Nigerian Universities.
The scheme bridges the gap existing between theory and practice of the Engineering and
Technology, Sciences, Agriculture, Medical, Environmental Sciences, Technical and Science
Education and other professional educational programmes in the Nigerian Tertiary Institutions.
It is aimed at exposing students to machines and equipment, professional work methods and
ways of safeguarding the work areas and workers in industries and other organizations.
The minimum duration of SIWES is 24 weeks (6 months). SIWES is a tripartite programme
involving the students, universities and the industries. The responsibilities of Students in SIWES
training programme is mainly of three stages: Pre-SIWES stage, SIWES stage and Post-SIWES
stage with its basic requirements.
1.1
AIMS AND OBJECTIVES OF SIWES
The objectives of SIWES are:
a. Provide an avenue for students in institutions of higher learning to acquire industrial
skills and experience in their courses of study;
b. Prepare students for the industrial work situations they are to meet after graduation;
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c. Expose students to work methods and techniques in handling equipment and machinery
that may not be available in their institutions;
d. Make the transition from school to the world of work easier, and enhance students
contacts for later job placement and
e. Provide students with an opportunity to apply their knowledge in real work situation
thereby bridging the gap between theory and practice
1.2 COMPANY PROFILE
Bel Papyrus Limited (BPL) is company that produces jumbo tissue paper through recycling of
waste paper, it is owned by a group of Lebanese, currently based at Plot 10, Block D Acme Road
Ogba Industrial Estate, Ikeja, and Lagos State, Nigeria. Incorporated In 1987, the company has
gone through management and business transformations over the years to emerge as a one of the
leading company producing jumbo tissue in Africa and the world at large. Bel papyrus exports
this jumbo tissue to African, Europeans, and other countries abroad.
Figure 1.1: Jumbo Tissue Produced by Bel Papyrus Ltd
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1.3 VISION
Our vision is aim at being the largest and the more renowned jumbo tissue paper manufacturer in
West Africa
1.4 MISSION
Our mission is to define our customers' needs and to fulfill them, providing them with products
and services of the highest quality and at the most competitive prices. We strive to stay ahead of
change and to become leaders in the region. And we want our success to inspire others, namely
our customers.
1.5 OBJECTIVES
i.
To deliver hard rolls (jumbo reels) those meets and even exceed customers’ expectations
at the lowest possible manufacturing cost.
ii.
To run the paper machine in the most efficient manner with minimum wastes and delays.
iii.
To maintain high productivity and reliability by operating the always at the optimum
speed.
iv.
To help in protecting the environment by discharging waste water and solid wastes in
accordance with government policies.
v.
To preserve the good names of the company and all its products by avoiding and
managing and disastrous events like chemical spillage and product contamination.
We believe that the best way to achieve our goal and live by our mission is to apply
environmentally friendly processes for continual improvement in all the phases of our operations.
This will contribute to our growth, to that of our customers and of the society we live in. We are
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confident that our success story will go on.
1.6 ORGANOGRAM OF BEL PAPYRUS LIMITED
General Manager Bel Papyrus Limited
Production
Manager
Manager
waste
paper
Technical
Manager
Tec
H.O.D Elect. &
instrumentation
Accountant Manager
auto
General
Director ABQS
mobile
Mechanical
manager (white)
Technicians
Interns
Manager
EHS
Departm
ent
Sales
Manager
H.O.D mechanical
department
Permane
nt staff
Preventive maintenance
supervisor
Personn
el
manager
Casual
staff
Mechanical
manager
(black)
Corrective
/shutdown
maintenance supervisor
Technicians
Project
Supervisor
Interns
Welder
Figure 1.2: company Organogram
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Interns
Interns
CHAPTER TWO
2.0 DESCRIPTION OF WEEKLY ACTIVITIES (WEEK 1 - 24)
During my internship at Bel papayrus ltd, our work is based on priority, when there is shut down
every mechanical personnel is deployed into the plant for the shut down after it over I.T student
is at liability to work with any mechanical section depending on the work at hand for that day
and number of personnel need for that day work. Mechanical sections are
• Preventive (PM) – greasing and Inspections
• Corrective – Repair
• Project – fabrication
2.1 KNOWLEDGE GAIN
2.1.1 SAFETY ORIENTATION; safety factors include all the measures carried out to protect
both the workers, contractors and all personnel present on the field at every given time
from fatalities and injuries. Safety precautions and guidelines includes
1. When personal protective equipment (PPE) is required for a specified job and location,
the use of such is mandatory.
2. Obey all the warning signage’s safety precautions rules and tag – out.
3. Never engage in horseplay in the workshop..
4. Always follow the lock- out/tag- out procedures when performing equipment repairs
5. Be always aware and alert of your surroundings.
2.1.2 CLASSIFICATIONS OF TOOLS AND MACHINE IN THE WORKSHOP
These are the tools I handled during my training at Bel papyrus limited. The workshop's
machines and equipment are classified under two major headings;
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1. Machines tools: these are tools that requires electrical power for its operation e.g hand
drilling machine, grinding machine, electric welding machine, and bearing heater
Figure 2.1: Drilling Machine
Figure 2.2: Grinding Machine
2. Hand tools: these are tools that don’t require electrical power for its operation. The hand
tools were further divided into different classes based on the work they are used for. The
classes are as follows:
a) Cutting tools: files, hacksaw, chisel, snips, pipe cutter
b) Driving tools: Allen keys, spanners, screw drivers, wrench
c) Measuring tools: vernier caliper, tri-square, tape rule, divider, micrometer
d) Spanners; range from 8 to 72 size of spanner such as: ring and flat, flat and flat, socket
and extension
2.1.3 PLANT MACHINE USES, OPERATION,
MACHINE COMPONENT
AND
MAINTENANCE I CARRIED OUT ON THOSE MACHINE IN SEQUENCE
1. DIP PULPER; this is the starting point of production, dip pulper machine is use to
disintegrate, pulp, blend the paper, when the waste paper enter into the pulper with the
aid of a conveyor there should be water and chemical inside the dip pulper, it should be
allowed to soak for 3 minutes and pulp for 7 minutes by then there is phase change from
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solid material to stock. After proper mixture it discharged to dumping thrasher with aid
of a discharged pipe at the bottom side of the pulper. It has a shaft supported by two
bearing it is intruded into the impeller attached with a nut extension with a bigger pulley
with a belt connecting it to a drive that is an electric motor that carry small pulley, which
agitate the machine when it been powered.
Figure 2.3: Dip Pulper Machine
Maintenance carried out in dip pulper
a) We replace the brush by welding it to the body, it located under the conveyor
b) Installation of guide
c) Belt tensioning
Figure 2.4: Brush
2. DUMPING POIRE UNIT; it screen out anything that is not paper, inside the dumping
poire unit it has a screening basket, rotor and impeller which is connected to a shaft
which is extended to a pulley support with a bearing, when the material is coming from
the discharged pipe it goes through the clearance (5mm) between the basket and the
dumping poire unit body the paper pass goes into the screening basket then it transfer to
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the dumping chest tank through a centrifugal pump the other material which is the reject
is then discharged to waste bin
Figure 2.5: Dumping Poire Unit
Maintenance carried out in dumping poire
a) We replace the valve
b) We remove the screening basket for cleaning
c) Welding of pipe
3. DUMPING CHEST TANK; this tanks has a capacity of 75000litres, it use to continue
the mixing operation, make batch into a continue process, it transfer by a centrifugal
pump to the high density cleaner. It has an impeller which is agitating the pulp presented
to allow proper flow. It impeller is connected to a shaft which is supported with two
bearing the shaft is attached to a bigger pulley with a belt connecting to a drive that has
an electric motor
Figure 2.6: Dumping Chest Tank
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Maintenance carried out in dumping tank
a) Replacement of rotating assembly
b) Coupling replacement
c) Replacement of valve
d) Belt tensioning
Figure 2.7: Coupling
Figure 2.8: Rotating Assembly
4. HIGH DENSITY CLEANER; it a density separator which screen out iron and sand
before transferring it to screen one. When the material is coming from dumping poire
tank through a centrifugal pump into the high density cleaner through its passage a fresh
water is introduced from the other side the impurity with high density will settle down
the low impurities will flow up to the next machine once the accumulation is high at the
down part it will eject out to the thrasher with the aid of a screw conveyor. High density
cleaner has a screw conveyor at the bottom, it has a shaft attached to the gear box and it
attached to the motor to the drive
.
Figure 2.9: High Density Cleaner
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Maintenance carried out in high density cleaner
a) Adjust the motor
b) Change valve
c) Oil of gear box with VGA 68 oil
5. SCREEN ONE; it make the flow uniformity, it has a screen basket attached to a rotor
which is connected to a shaft pulley and a belt connecting it to the drive pulley, the
distance of the screening basket to the body of the screen on is 3mm
Figure 2.10: Screen One
Maintenance carried out in screen one
a) Remove the screening basket for cleaning and installing new basket
b) Belt tensioning
c) Replacement of valve
Figure 2.11: Screening Basket
6. LOW DENSITY CLEANER; it also a density separator , it further clean fiber, it has a
screen basket attached to rotor which is also attached to a motor
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Figure 2.12: Low Density Cleaner
7. DEINKING CELL; it remove ink, it has three ejector which force paper with air
through a hole to enter into the cyber cell once it enter into the deinking cell a lot of
amount of water is presented once the paper coming from the ejector enter the accept
flow top of the water then it transfer by centrifugal pump to the washer then the reject is
sent to foam tank
Figure 2.13: Deinking Cell
Maintenance carried out in deinking cell
a) Replacement of coupling
b) welding of pipe
c) change of valve
d) Replacement of centrifugal pump
8. DNT WASHER; fresh water is introduced to remove impurities, fiber coming from the
deinking cell through the centrifugal pump will passed through a head box is flowing
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directed to the groove roller inside the wire washer it will groove it by the aids of wire it
transfer to crouch roller it will crouch it both of the roller supported by the bearing the
fiber is then drop under the wire washer there is a discharge pipe which transfer it to the
screw presser. The crouch roller is connected to a drive and the wire is connecting both
groove and crouch roller together.
Figure 2.14: DNT Washer
Maintenance carried out in DNT washer
a) change of groove roller
b) replacement of wire
c) welding of it cover
Figure 2.15: Wire
Figure 2.16 Groove Roller
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9. KRIMA; combination of screw press, plug screw, shredder, pre heater, infeeder. it
remove excess water and introduce steam into the material, fiber coming from the
discharge pipe of the washer once it enter into the krima it cannot be pump. It has a
screw roller connected to a gear box which is directly connected to a motor, when it
rotating it screw pressed it
Figure 2.17: Screw
Press Figure
2.18: Plug
Screw
Figure 2.19:
Shredder
Figure 2.20:
Pre Heater
Maintenance carried out in krima
a) replacement of screw roller
b) Installation of support
c) Installation of damper
d) Oil of gear box with VGA 68 oil
Figure 2.21: Damper
Figure 2.22: Screw Roller
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Figure 2.23: Gear Box
Figure 2.24: Replacing Screw Roller
10. DISPERGER; it improve fiber quality and it reduce the size of contaminant fiber
coming from the infeeder fiber is strong the disperger will break it, evenly separate it
into small particle, it has a disk movable and stationary disk the movable disk is attached
to a drive to move it, while the other is held stationary the fiber goes in between the disk
as it coming from infeeder. It has hydraulic use to expand it
Figure 2.25: Disperger
Maintenance carried out in disperger
a) replacement of disk
b) replacement of coupling
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Figure 2.26: Coupling
Figure 2.27: Disperger Disk
11. BLEACHING TANK; complete the bleaching; it has an impeller which is agitating the
tank presented to allow proper bleaching. It impeller is connected to a shaft which is
supported with two bearing the shaft is attached to a bigger pulley with a belt connecting
to a drive that has an electric motor
Figure 2.28: Bleaching Tank
Maintenance carried out in bleaching tank
a) Change of pump
12. STORAGE TANK; store fiber, It has an impeller which is agitating the pulp presented
to allow proper flow. It impeller is connected to a shaft which is supported with two
bearing the shaft is attached to a bigger pulley with a belt connecting to a drive that has
an electric motor
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Figure 2.29: Storage Tank
Maintenance carried out in storage tank
a) Change of pressure gauge
Figure 2.30: pressure gauge
13. MACHINE TANK; store material waiting to be transfer to machine by a centrifugal
pump, It has an impeller which is agitating the pulp presented to allow proper flow. Its
impeller is connected to a shaft which is supported with two bearing the shaft is attached
to a bigger pulley with a belt connecting to a drive that has an electric motor
Figure 2.31: Machine Tank
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Maintenance carried out in machine tank
a) Change of centrifugal pump
b) Belt tensioning
14. MIXING TANK; store the excess fiber from the machine tank. It has an impeller which
is agitating the pulp presented to allow proper flow. Its impeller is connected to a shaft
which is supported with two bearing the shaft is attached to a bigger pulley with a belt
connecting to a drive that has an electric motor
Maintenance carried out in mixing tank
a) Replacement of centrifugal pump
15. MACHINE REFINER; It elongate the fiber paper, it make it more softer and refined, it
has two disk movable and stationary disk, the movable disk is slot to a shaft attached to
a rotating assembly connecting the drive. It has a gear box at the front side with it own
motor to engage and disengage the disk at the proper time.
Figure 2.32: Machine Refinder
Maintenance carried out in machine refinder
b) Replacement of disk
c) Installing of gland packing
d) Replacement of coupling
e) Rotating assembling
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Figure 2.33: Disk
Figure 2.34: Rotating assembling Figure 2.35: gland packing
16. PIT/ FAN PUMP; create a high pressure to take the material to the pressure screen. It
has two impellers inside the pump connected to motor to drive it, there the pressure
created when the product is coming from the refiner into the pit, high pressure is created
by the fan pump to take it up
Figure 2.36: Fan Pump
Maintenance carried out in fan pump
a) Replacement of coupling
b) Welding of pipe
c) Installation of clip
17. PRESSURE SCREENING; it removes dirt before it send it to the machine. Fiber
coming from the fan pump is been screen by the pressure screen there is a basket inside
the pressure screen the distance between the basket screen and the body is 0.2mm as the
fiber is coming from the side of the pressure screen it enter into the clearance the fibre is
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in small particle it enter into the basket while it rolling the accept flow into the head box,
it basket is attached to the rotor, the rotor is connected to a shaft at the down when the
pulley is attached there is a belt connecting both pulley and electric motor.
Figure 2.37: pressure screen
18. HEAD BOX, FORMING ROLL AND SUCTION PRESS ROLL;
a) Head box; it spilt the matter into 14 gram per ms
b) Forming roll; it a roller forming the material, this where the wire and felt meet
c) Suction press roller; it dry water from the material, it is supported by two bearing
Figure 2.38: Combination of Head Box, Forming Roll and Suction Press Roll
Maintenance carried out in head box, forming roll and suction press roll
a) Replacement of wire
b) Greasing of machine and oiling machine with VGA 220 oil
c) Installation of walk rail
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d) Replacement of felt
e) Replacement of suction press roll
Figure 2.39: Suction Pres Roller
Figure 2.40: Felt
Figure 2.41: Wire
19. YANKEE DRYER; it dry the paper when it passing through a big roller it take it from
the wet side pass through the hot side that how it dry it. The yankee has a big roller
supported by two bearing a shaft at one end is attached to a gear box and connecting it to
the motor inside that big roller steam is been introduced both inside the yankee and on
top
Figure 2.42: Yankee Dryer
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Maintenance carried out in Yankee dryer
a) Grinding of roller
b) Replacement of hose
c) Greasing of machine and oiling with VGA 220 oil
d) Replacement of rotary joint
e) Replacement of steam nozzle
Figure 2.43: Rotary Joint
Figure 2.44: Greasing Tower
Figure 2.45: Hose
20. REWINDER; tissue coming out from yankee dryer is usually hard, rewinder make it
more softer. They place the jumbo tissue into the rack and it passes through some roller
to roll it to the required size needed
Figure 2.46: Rewinder
Maintenance carried out in rewinder
a) Greasing of machine
b) Change of roller
c) Replacement of blade
d) Belt replacement
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21. NYLON PACKING; after rewinding it, they roll the jumbo tissue paper to the nylon
packing machine, where it been nylon.
Figure 2.47: Nylon Packing
2.1.4 TUBE STEAM BOILER: 18 BAR, 210 DEGREE CENTIGRADE STEAM
BOILER CLEANING THE FIRING ROD AND FIRING TUBE
A boiler is a device used to create steam by applying heat energy to water. The capacity of the
boiler should have ten liters of water and the working pressure must be 3.4 Kgf/cm2 (kilogramforce.
The Function of Steam Boiler; the main function of a steam boiler is producing, storing,
troubling the vapor and then it converts into steam at the required pressure as well as
temperature.
Steam Boiler Working Principle; Boiler is one type of closed device in the shape of a
cylindrical. The capacity of the boiler to have steam, as well as water is sufficient. Generally, the
liquids are stored in the boiler for generating steam by burning the fuels or applying the heat
energy at different conditions of pressure based on the size of the vessel as well as specifications.
Finally, the steam in the boiler supplies using a pipe and flows into various industries like plants.
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The main components of this boiler mainly include: shell, furnace, grate, mountings, water
space, accessories, refectory, and level of water, scale, foaming, lagging, and blowing off
The kind of boiler we use in Bel papayrus ltd is a Water Tube Boiler
Figure 2.48: Water Tube Boiler
The water tube boiler is one type of boiler, and the main function of this boiler is the water in the
tube will be heated to generate the vapor. The main benefits of this boiler are, used in huge
thermal power-stations. By using a number of water tubes a big heating surface can be attained.
The water movement is much faster, so the heat transfer rate is very high which consequences to
high-efficiency. This type of boilers requires fresh water as well as water treatment plants to
maintain the necessary quality of water tube boiler.
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Figure 2.49: Cleaning Inside the Firing Tube Where the Firing Sit
2.1.5 WELDING AND FABRICATION
Welding is a fabrication or sculptural process that joins materials, usually metals or
thermoplastics, by using high heat to melt the parts together and allowing them to cool causing
fusion.
ARC WELDING IS WHAT WE USE IN PAPAYRUS LTD; These processes use a welding
power supply to create and maintain an electric arc between an electrode and the base material to
melt metals at the welding point. They can use either direct current (DC) or alternating current
(AC), and consumable or non-consumable electrodes.
Metal Fabrication is the creation of metal structures by cutting, bending and assembling
processes. It is a value-added process involving the creation of machines, parts, and structures
from various raw materials.
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Figure 2.50: Welding Of Bob Cat Carrier
Figure 2.51: Cutting Of 100mm By 100mm I Beam
Figure 2.52: Fabrication of Support With A
100mm By 100mm I Beam Figure
2.53: Fabrication of Cover For Panel
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Figure 2.54: Drilling a 10mm Thickness metal Plate With 16mm Drilling Bit
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CHAPTER THREE
3.0 CONCLUSION
In summary, I can say that my 6 months Industrial Attachment at Bel papyrus ltd was a huge
success and a great time of acquisition of knowledge and skills. This SIWES attachment was a
privilege and I never regretted exploring it because of the massive practical knowledge I tapped.
It was a fulfilling and an expository experience as it helped improve my knowledge generally on
what life is like outside school and learning environment. It has helped me know what it is like to
work in an organization, and what to expect after school when working, also what it is like to do
your job right and to do it at the right time in order to avoid any form of query.
My training has helped me improve in my course of study; and through my training I was able to
appreciate my course of study even more, because I had the opportunity to blend the theoretical
knowledge acquired from school with the practical hands-on application of knowledge gained
here to perform tasks to produce a successful result. It also helped me improve on my
communication and presentation skills; and developed a good relationship with my colleagues at
work. The SIWES program also helped me to choose a reasonable career path for myself.
3.1 CHALLENGES
1. I.T Attachment Difficulty
2. As a result of my inexperience, a lot of activities were carried out solely by the
machinists as to avoid novice work done. Since they had spent years in the field therefore
interns who have less or no experience could do nothing much. Safety was of prime
importance and so protection was made available at least up to reasonable level.
3. Distance was another main challenge which really caused some kind of inconvenience.
4. Financial Incapacity
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5. Cost of Feeding
3.2 RECOMMENDATION.
1. Prospective students should seek internship in establishments with goals similar to their
aim.
2. The university should try to collaborate with some industries in order to get easy
placements for students.
3. ITF should make monthly allowance available for students at times due, so as to put an
end to financial difficulties that may arise during the course of the program.
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REFERENCES
1. SIWES (2008). Retrieved January 2015, from ITF: http://odich.com/itfnig/siwes.php
2. Organogram of Bel papyrus ltd, Retrieved January 2 2020, from; Bel papyrus ltd Admin
Manager office
3. Machine pictures, Retrieved December 22, 2019, from; Bel papyrus ltd plant
4. Safety orientation; Retrieved January 15, 2020, from
https://en.m.wikipedia.org/wiki/Environment,_health_and_safety
5. plant machine uses, operation, machine component Retrieved January 3, 2020, from Bel
papyrus ltd manufacturer hand books
6. Tube
steam
boiler.
Retrieved
January
https://en.m.wikipedia.org/wiki/boiler
7. welding and fabrication; Retrieved January 15, 2020, from
https://en.m.wikipedia.org/wiki/ welding_and_fabrication
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15,
2020,
from