A TECHNICAL REPORT ON STUDENTS’ INDUSTRIAL WORK EXPERIENCE SCHEME (GPH 384) Written by MUSTAPHA MODINAT MOSUNMOLA (15/56FJ035) Of the Department of Applied Geophysics, Faculty of Physical Science, University of Ilorin. JUNE - NOVEMBER 2018. ACKNOWLEDGEMENT First and foremost, I give all praises and adoration to ALMIGHTY GOD who in His infinite mercy made the work experience programme a successful, experience filled and memorable one. It is He who has and will always been the unshakeable pillar. Secondly, my profound gratitude and sincere appreciation goes to the most wonderful family in the world, my guardian, and the souls behind every successful step, my siblings. I say with pure heart that you all are irreplaceable. Thanks for the support in all ramification. You all remain indispensable. More importantly, I must show my sincere appreciation to all the staffs of the Geotechnical laboratory for their immense support and guidance during the training period. I am very grateful for the irreplaceable knowledge you have impacted on me. CHAPTER 1 1.0 INTRODUCTION In the early stages of science and technology education in Nigeria, students that graduated from tertiary institution in the nation had neither little or no technical knowledge nor working experience. It was in this view that students undergoing science and technology related courses were mandated to undergo industrial attachment in the view of widening their horizons and enabling them have technical knowledge or working experience before graduating from their various institutions. 1.1 BACKGROUND AND HISTORY OF SIWES In October 1971 a Decree was pronounced by the then General Gowon led military government and it had the objective of promoting and encouraging the acquisition of skills in industry and commerce. This was done to generate a pool of indigenously trained manpower which will be sufficient to meet the economic needs of the nation. The Industrial Training Fund (ITF) established the Students’ Industrial Work Experience Scheme (SIWES) in 1973. It started in 1974 with 748 students from 11 institutions of higher learning participating. By 1978, the scope of participation in the scheme had increased to about 5,000 students from 32 institutions. The Industrial Training Fund, however, withdrew from the management of the scheme in 1979 owing to problems of organizational logistics and the increased financial burden associated with the rapid expansion of SIWES. Consequently, the Federal Government funded the scheme through the National Universities Commission (NUC) and the National Board for Technical Education (NBTE) who managed SIWES for five years (1979 – 1984). The supervising agencies (NUC and NBTE) operated the scheme in conjunction with their respective institutions during this period. The scheme was subsequently reviewed by the Federal Government resulting in Decree No 16 of August, 1985 which required that “all students enrolled in specialised engineering, technical, applied sciences and applied arts should have supervised industrial attachment as part of their studies”. In the same vein, the ITF was directed by the Federal Government to take charge and resume responsibility for the management of SIWES in collaboration with supervising agencies, i.e. National University Commission (NUC), the National Board for Technical Education (NBTE) and the National Commission for Colleges of Education (NCCE). 6 | P a g e Following the resumption of management of SIWES by the ITF in 1984, the scheme has witnessed rapid expansion. Between 1985 and 1995, the numbers of institutions and students participating in SIWES rose to 141 and 57,433 respectively. Between 1995 and 2003, a total of 176 institutions and 535,210 students participated in the scheme. In 2008 alone, the number of institutions which participated in SIWES rose to 204 while the number of students from these institutions who participated in the scheme was 210,390. Presently, participation in the scheme is limited to Science, Engineering and Technology programmes in universities and polytechnics while in the Colleges of Education, NCE programmes in Technical Education, Agriculture, Business, Creative Arts & Design, Computer Studies and Home Economics are eligible 1.2 OBJECTIVES OF SIWES a) To provide an avenue for students in institutions of higher learning to acquire industrial skills and experience during their courses of study; b) To provide students with the opportunities to apply their educational knowledge in real work situations, thereby bridging the gap between theory and practice; c) To prepare students for industrial work situations that they are likely to meet after graduation; d) To expose students to work methods and techniques in handling equipments and machinery that may not be available in their institutions; e) To make the transition from school to the world of work easier and enhance students’ contacts for later job placements; f) The scheme helps the student in developing intellectual skills as they are often left on their own to take technical decisions and often analyze complex interdisciplinary problems and proffer appropriate solutions applicable to real situations. CHAPTER 2 2.0 DESCRIPTION OF ESTABLISHMENT OF ATTACHMENT Samonda metal construction company limited offers welding services in the production of gates, Iron doors, Iron production and any other production involving the use of several welding and fabrication techniques. It is located at plot 1 block VI km 5 ilesha Owo express RD, Akure, Ondo. 2.1 LOCATION AND BRIEF HISTORY. SAMONDA METAL CONSTRUCTION COMPANY LTD was incorporated in AKURE, Nigeria with Registration Number 815375. It was registered on 30 Apr 2009 Samonda metal construction company limited . was founded in 2009 by a seasoned welder and entrepreneur with a vision to establish a leading welding and fabrication company that could meet the growing demands of the industrial and construction sectors. In its initial years, Samonda metal construction company limited focused on providing custom welding and fabrication solutions for local businesses. The company quickly gained a reputation for its commitment to quality craftsmanship and attention to detail. As demand for its services increased, Precision Steelworks expanded its facilities and workforce. As the company continued to thrive, it expanded its operations beyond its original location, establishing satellite offices in key industrial hubs.Samonda metal construction company limited also diversified its services, offering not only structural steel fabrication but also providing solutions for architectural metalwork, industrial piping, and pressure vessel fabrication. Throughout its history, Samonda metal construction company limited has maintained a strong commitment to its local community. The company has supported various charitable initiatives, vocational training programs, contributing to the development of skilled professionals in the welding and fabrication field. As of the present day, Samonda metal construction company limited . stands as a well established and respected name in the welding and fabrication industry. The company continues to push boundaries, embracing cutting-edge technologies and sustainable practices, ensuring its continued success in the ever-evolving field of metal construction. 2.2 OBJECTIVES OF THE COMPANY The laboratory was set up to Ensure high-quality welding and fabrication services that meet or exceed industry standards. Implement quality control measures to consistently deliver reliable and durable products. development strategies. 2.3 COMPANY NETWORK 2.4 THE VARIOUS DEPARTMENTS / UNIT IN THE ESTABLISHMENT AND THEIR FUNCTIONS ADMINISTRATION DEPARTMENT ACCOUNT DEPARTMENT ENGINEERING LABORATORY DEPARTMENT PROJECT DEPARTMENT CHAPTER THREE 3.1 INTRODUCTION During the course of my training with the Mechanical engineering and logistics unit of the Directorate, which comprise of Welding and Fabrication unit, refrigeration and airconditioning unit, Motor vehicles and logistics unit and plants and machinery unit, I was able to take part in some work done which includes; a) Production work in the metal welding and fabrication workshop. b) Repair/maintenance work at the refrigeration and air-conditioning unit. c) Installation of air-conditioning unit. d) Maintenance work of some buildings and other structures/facilities through the welding and fabrication unit. e) Use of chain link and galvanize wire to fence some of the University properties/buildings. f) The maintenance of lecture halls in the University community. 3.2 WELDING AND FABRICATION UNIT Welding is a process for joining two similar or dissimilar metals by fusion. It joins different metals/alloys, with or without the application of pressure and with or without the use of filler metal. The fusion of metal takes place by means of heat. The heat may be generated either from combustion of gases, electric arc, electric resistance or by chemical reaction. During some type of welding processes, pressure may also be employed, but this is not an essential requirement for all welding processes. Welding provides a permanent joint but it normally affects the metallurgy of the components. It is therefore usually accompanied by post weld heat treatment for most of the critical components. The welding is widely used as a fabrication and repairing process in industries. Some of the typical applications of welding include the fabrication of ships, pressure vessels, automobile bodies, off-shore platform, bridges, welded pipes, sealing of nuclear fuel and explosives, etc. Most of the metals and alloys can be welded by one type of welding process or the other. However, some are easier to weld than others. To compare this ease in welding term ‘weldability’ is often used. The weld ability may be defined as property of a metal which indicates the ease with which it can be welded with other similar or dissimilar metals. 3.2.1 CLASSIFICATION OF WELDING PROCESSES A. Based on the state of the material during welding (plastic or molten): a) Plastic welding or pressure welding b) Fusion welding or non-pressure welding B. Based on the source of heat: a) Gas welding: oxy-acetylene or hydrogen welding; air-acetylene welding b) Arc welding: carbon arc welding; metal arc welding; tungsten arc welding; etc c) Resistance welding: spot welding; projection welding; etc. d) Thermit welding e) Solid state welding: friction welding; diffusion welding; forge welding; etc f) New welding processes: laser beam welding; brazing welding; arc weld etc. During the period of my internship, I learned extensively and practically about the Electric Arc Welding. Below is a bit of what I understand about Arc Welding. 3.2.2 ELECTRIC ARC WELDING PROCESS Arc welding is one of several fusion processes for joining metals. By applying intense heat, metal at the joint between two parts is melted and caused to intermix – directly, or more commonly, with an intermediate molten filler metal. Upon cooling and solidification, a metallurgical bond is created. Since the joining is an intermixture of metals, the final weldment potentially has the same strength properties as the parts. This is in sharp contrast to non-fusion processes of joining i.e. soldering, brazing etc in which the mechanical and physical properties of the base materials cannot be duplicated at the joint. In arc welding, the intense heat needed to melt metal is produced by an electric arc. The arc is formed between the actual work and an electrode is it sticks or wire that is manually or mechanically guided along the joint. The electrode is a specially prepared wire or rod that not only conducts the current but also melts and supplies filler metal to the joint. Figure 3.1: Electric Arc Welding 3.2.3 EQUIPMENT USED IN WELDING AND FABRICATION The various equipment required in welding and fabrication workshop include: a) Welding machine: The welding machine used can be AC or DC welding machine. The AC welding machine has a step-down transformer to reduce the input voltage of 220-440V to 80-100V. The DC welding machine consists of an AC motor generator set or diesel/petrol engine generator or a transformer rectifier welding set. b) Welding cables: Welding cables are required for current from power source through the electrode holder, the arc, the work piece and back to the welding power source. They are insulated copper or aluminium cables. c) Electrode bolder: Electrode holder is used for holding the electrode at a desired angle. These are available in different sizes, according to the ampere rating from 50 to 500 amperes. d) Ground and ground clamp: This is the lead that ground this is the lead that ground e) Welding electrode: An electrode is a piece of wire or a rod of metal or alloy, with or without coatings. An arc is set up between electrode and work piece. Welding electrode are classified into two types: Consumable electrodes (bare and coated electrodes like heavy, light and shielded arc electrode); and Non-Consumable electrodes (carbon or graphite electrodes and tungsten electrodes). Consumable electrodes are made up of different metals and their alloys. The end of this electrode starts melting when the arc is struck between the electrode and the work 18 piece. Consumable electrode acts as filler metal. Non-consumable electrodes are made up of high melting point materials like carbon, pure tungsten or alloy tungsten etc. these electrodes do not melt away during welding but practically, the electrode length goes on decreasing with the passage of time, because of oxidation and vaporization of the electrode material during welding. During the course of my internship the commonly used electrode was the consumable electrode. f) Chipping hammer: Chipping hammer is used to remove the slag by striking. g) Wire brush: Wire brush is used to clean the surface to be weld. h) Protective clothing: Used to protect the hands and clothes of the welded from the heat, speak, ultraviolet and infrared rays. i) Face shield: Protects the eyes and face from harmful particles and rays. Figure 3.2: Electric Arc Welding Set-up CHAPTER FOUR EXPERIENCE, METHODOLOGY AND EQUIPMENT 4.1 GENERAL TRAINING EXPERIENCE During my SIWES (Students Industrial Work Experience Scheme) which is aimed at exposing and preparing students for actual work experience on my chosen career, I had the opportunity to see design and fabrication process in its real sense and reality, I witness how artisans as well as skilled operatives are managed, how refrigeration and air-conditioners are diagnose and repair, how materials are put to use especially when it comes to measurement and cutting and how work generally progressed from one stage to another. This has bridged the great gap between the theory taught to me by my lecturers and the actual field work and it has also uncovered me to know some of the applied aspect of my field of study. 4.2 METHODOLOGY IN WELDING AND FABRICATION The methods used to carry out works during my SIWES program at the welding and fabrication unit under mechanical department of the directorate of physical facilities are; a) Using electric arc welding for metal production/fabrication b) Fencing job using chain-link and casted metal poles c) Maintenance work of different kinds (metal work) etc. The supervisor in charge of the workshop started by orienting us on the scheme of work to do. He made emphasis on the importance of learning about measurement, need of tolerances when measuring, measuring tools, marking tools, cutting tools, work holding devices, loosening and tightening tools. ➢ Measurement is the act of obtaining a given length/distance that is use to describe or produce an item. There is different measuring device, but in this unit, we mostly make use of tape rule/tape measurement and steel rule. Measurement is taken in centimetre or in inches. ➢ Marking: marking is the act of taking note at the point you want to work on and to do this, one needs tools called the marking tools e.g., scriber, divider etc. ➢ Cutting tools: this is an act of making an opening on a work piece or dividing into pieces especially with a sharp tool e.g., hacksaw, cutting machine, chisel, drill etc. ➢ Driving tools: E.g., hammer a tool with a heavy metal on a long handle. A hammer is a tool meant to deliver an impact to an object. Works carried out in the unit at the course of my internship are: 1. Construction of a local charcoal pod Material used: 1ft flat bars, rim of a motor car, 1 x 1 square pipes Steps: ➢ measurement and cutting of flat bars of various sizes; 22inch, 19inch, 17inch, 14.5inch ➢ the cutting was done using a hack saw on a bench vice ➢ The bars were welded together inside the rim Figure 4.1: A local charcoal pod ➢ cutting operation commences of square pipes of length 2ft using hack saw on bench vice into three ➢ after cutting, we weld the square pipe on the body of the rim ➢ after welding, we used the welding machine to bore holes on the rim 2. Reinforcement of square pipes at ICT University of Jos Permanent Site Materials used: 1 x 1 square, paint Steps: ➢ Firstly, obtain the measurement of the exiting burglary was carried out. ➢ Cutting of pipes was carried out using cutting machine ➢ After cutting, we use tri-square, scribe and the cutting machine to chamfer the edges of the square pipes in 30, 45, 60, and 90 degrees ➢ Edge preparation was then done i.e., bevelling of the edge of the pipe ➢ We assemble all members to the require shape of square pipe and tack with the welding machine. ➢ After tacking the joint, square gauge was use to ensure angles are in perfect square after which proper welding was done at all the joint. ➢ We paint the work to give it a nice look 3. Fencing work Material used: poles and chain link. Steps: ➢ Firstly, obtain the fence plan having the complete dimension overview of the property along with the fence outline (height of fence and distance of the pole to each other) ➢ We mark the property line (boundary) using line. ➢ Then we mark the poles’ location on the boundary line giving a distance of 3m between each pole. ➢ Digging of the mark points begins; the holes were dug 2ft deep. ➢ The metal poles were then casted with concrete and allow to solidify for two days. ➢ We then used the G.I wire to bind the poles together through the created holds on the pole. ➢ We fix the chain link the poles and bonded it using the binding wire. 4. Construction of a burglary frames for twin theatre doors Materials used: 1 by 1square pipe, and Steps: ➢ A design sketch of the proposed frames burglary was obtained with all the necessary measurement needed. The dimensions of the doors are as follows: 3ft x 80” inches open outright (D3) door; 35 x 80 inches- open outright (D2) door; 28 x 80 inches – outside (D1) door; and 8f t x 110 inches ➢ For Door 3 (D3) • We cut the needed materials to the required measurement; 1½ by 1 ½ inch square pipe We cut 25½ inch for the width of the burglary frame = 4 members (2 members for each swing). 79inch for the height = 4 members (2members for each swing) • We did the edge preparation (bevelling) for the members. • We cut a 12mm rod of 75 inches across the weight of the frame’s door • We cut a 1by 1 square pipe of 6 x 79inches for both the width and height for collapsible burglary frame= 4 members (2 members for each swing) • The members are then assembling and tack weld according to their position. Using the tri- square we ensure the members are perfectly squared. • The final welding is then done after squaring of the frame • We grind the welded part so as to be smooth for good looks and so • Gate hinges and lock were then welded to each of the two-swing gate for opening and closing (2 hinges for each and a lock at the mid span of the gate joining). • All rough edges on the gate were grinded smooth • The frame was lastly painted with anti-rust paint ➢ For Door 2 (D2) • We cut the needed materials to the required measurement; 1 by 1-inch square pipe • We cut 32½ inch for the width of the burglary frame = 4 members (2 members for each swing). 79inch for the height = 4 members (2members for each swing) • We did the edge preparation (bevelling) for the members. • We cut a 12mm rod of 75 inches across the weight of the frame’s door Figure 4.4: Door 2 • We cut a 1by 1 square pipe of 5 x 79inches for both the width and height for collapsible burglary frame= 4 members (2 members for each swing) • The members are then assembling and tack weld according to their position. Using the tri- square we ensure the members are perfectly squared. • The final welding is then done after squaring of the frame • We grind the welded part so as to be smooth for good looks • All rough edges on the gate were grinded smooth • The frame was lastly painted with anti-rust paint ➢ For Door 1 (D1) • We cut the needed materials to the required measurement; 1 by 1-inch square pipe • We cut 32½ inch for the width of the burglary frame = 4 members (2 members for each swing). 78inch for the height = 4 members (2members for each swing) • We cut a 12mm rod of 75 inches across the weight of the frame’s door • We did the edge preparation (bevelling) for the members. • The members are then assembled and tack weld according to their position. Using the tri- square we ensure the members are perfectly squared. • The final welding is then done after squaring of the frame • We grind the welded part so as to be smooth for good looks and so • Gate hinges and lock was then welded to each of the two-swing gate for opening and closing (2 hinges for each and a lock at the mid span of the gate joining). • All rough edges on the gate were grinded smooth • The frame was lastly painted with anti-rust paint • Also, cutting of 1½ by 1½ square pipe was carried out with the dimension of 8ft x 110 • Welding of hinges on the burglary frame was carried out 5. Construction of burglary proof doors and windows Materials used: for window 17 x 20, 1 ½ by 1½ square pipes, 12mm metal rod. Steps: ➢ Design and measurement are the first step taken ➢ Cutting of the materials according to required measurement ➢ Assembling of the material for frame making, then tack weld and squaring ➢ Proper welding of the joints, after which the frame was measured. ➢ The measurement of the frame in to in was transfer on the rod, mark and then cut ➢ The cut rod was then arranged in an orderly design and welded to the frame with a uniform spacing between each rod ➢ Painting is the last step taking 6. Construction of burglary frame door with its collapsible burglary Materials used: square pipe of 1½ by 1½ was used and 12mm rod Steps: ➢ We cut it into the following dimensions; 31 x 77-inch, 31½ x 77, 31 x 78 each into two equal halves ➢ We cut the same square pipe for the collapsible burglary with the following dimension; 6 x 77-inch, 7 x 77-inch, 5 x 77 inch respectively ➢ We cut the 12mm rod into different seizes ➢ The members are then assembled and tack weld according to their position. Using the tri- square we ensure the members are perfectly squared. ➢ The final welding is then done after squaring of the frame ➢ All rough edges on the gate were grinded smooth ➢ The frame was lastly painted with anti-rust paint 4.3 SUMMARY In summary, these are the steps for arc welding process: ➢ Mark measurement on the on the object to be fabrication ➢ Get or make a fabrication sketch or design/drawing and develop a well thought out step by step procedure. ➢ Gather tools and materials. ➢ Put together a cut list, lay out and cut the materials. ➢ Make edge preparations and clean the metal areas to be welded. ➢ Position and clamp materials prior to welding. ➢ Tack weld assemblies, check the dimensions, setup and squared. ➢ Place the final welds and assemble the final fabrication. ➢ Grind welds smooth only if necessary. ➢ Lastly, paint the fabrication if needed. 4.4 EQUIPMENT USED Equipment/machines used or handled in the welding and fabrication unit in executing the above works are; Welding machine, Grinding/cutting machine, welding table, measuring tape, Cutting plier, Flat head, Phillips’s screwdriver, Round and flat files, Callipers, Welding clamp/table clamp, Hack saw, Cold worked chisel, Switch box, chipping hammer, Earth clamp, Protective eye glass, and Monday hammer. 4.5 SAFETY PRECAUTION a) The welder undivided attention is required while handling the machine. b) Proper safety clothing should be worn. c) Joint should be properly welded d) Care should be taken when handling the electric connection. e) Horse ply should not be done in the workshop completely. CHAPTER FIVE OBSERVATIONS, RECOMMENDATIONS AND CONCLUSION This report vividly describes the activities of Student Industrial Work Experience Scheme as well as supporting documentation for six-month Industrial Training. It was a scale necessary for evaluating up student achievement. It was a dream comes through being able to achieve the targeted objectives. During this six-month industrial training I put what was taught me in class theoretically into practical aspect. 5.1 OBSERVATIONS During the program, some observations were made and they are as follows: a) To achieve quality work, experienced professional engineers were employed to supervise and direct on all work to be done. b) To carry out the set work, good qualified artisans/craftsmen are directed to carry out the work. c) For one to be able to handle a unit, one must have good leadership qualities and great management skills. d) All equipment should be available and in good working condition before starting a work/job e) Safety measures are not properly observed by craftsmen f) When craftsmen are not properly supervised, they rely on past experience instead of following the work schedules and specification. g) Students on SIWES were not properly taken care of especially with regards to their safety. h) I observe that material selection is a major factor to consider in production. i) Joint preparation enhances the strength of a good job. j) Observe all safety measures during working hours in the welding unit and the refrigeration and air conditioning unit. k) At the refrigeration and air-conditioning unit, I observe that moisture content and dirt can easily be introduce to the system through leakage, during and repairs or during changing of lubricant l) I observed that complete attention and focus is needed when handling any component and tool/equipment. 5.2 DIFFICULTIES ENCOUNTERED DURING THE TRAINING a) Faulty machinery, tools and materials. b) Lack of standardization of laborers. c) Lack of enough safety materials such as cloths, safety boots, hand gloves and helmets etc d) No proper motivation. e) Had difficulty in understanding to some of the workshop technician’s terminologies due to the level of education. f) Have issue of safety kits g) Some of the laborers on site were difficult to relate with. h) Delay of materials to the sites such as irons, refrigerants etc. 5.3 POSSIBLE SOLUTIONS a) Professional engineers should always endeavour to supervise and have firsthand look on what is happening. b) Working machinery, standard tools and materials should be provided. c) Supervision should be carried out frequently/regularly to avoid any deviation. d) Vehicles should be made available to convey workers to and fro from site. e) Safety kit should always be provided for workers. f) Students on internship should be motivated by organizations. 5.4 RECOMMENDATIONS With regards to my experience during my SIWES program, I hereby recommend that: a) There should be an extension of the program because six months is barely enough to gain so much experience especially for engineering students. b) ITF should always make it as a duty to visit students in their various places of their attachment. c) Foremen should be given adequate motivation to enable them relate vital information to the SIWES students. d) Students should be given reasonable financial motivation to make them have a feel of ‘He that works let him feed’. e) Institutions, ITF and the Federal Government should work in collaboration to ensure students gain full acceptance in places of attachment. f) The organization should endeavour to given proper orientation to all SIWES student on how the organization is running, the dos and dons of their establishment 5.5 OVERALL SUMMARY The aim of this report is to assists the institute to know the knowledge/experience acquire by me during my SIWES program. The IT period spent with the Directorate of Physical Facilities; University of Jos was very interesting because it exposed me to the practical aspect of my profession taught in school. The experience I gained during this period will help me in understanding my course of study and life as it has improved my knowledge and interaction skills. 5.6 CONCLUSION The importance of SIWES program cannot be overemphasized as it helps me (students) in acquiring the needed skills in my field of study. The program also enables me to understand the importance of my courses and also to appreciate it more. Supervision from my supervisor was encouraging as expected as it buster my confidence. The six months period was not sufficient to achieve the required level of Practice. Funding of construction projects and a lot of logistic problems makes it difficult for us to acquire massively. The period of the training was fully utilized and quite impacting, during this period, most of the process of engineering production, servicing and installation was learned and achieved. The existing gap between theory and practice has drastically reduced as I carefully followed each stage of work done during the training. Finally, my deep gratitude goes to the coordinators of SIWES and Directorate of Physical Facilities for granting me the opportunity to get access to the organization and participate in rewarding activities.