Final Technical Report-201303531 PDF

Prince Muhammad Bin Fahd University
College of Engineering
Department of Mechanical Engineering
Final Technical Report

At:
Reporting Period 7th July, 2019 to 18th July, 2019

Student I.D. 201303531
Student Name Faisal Al-Shamrani
Internship Advisor Dr. Faramarz Djavan Roodi
Course Code MEEN 3301
SUMMER – 2019
Abstract
This report provides an insight to my 8 weeks internship tenure throughout the summer
semester and delivers some of the very valuable experience I have ever had during my training
in an organization that was biased towards a mechanical environment of work and operations.
I was appointed as a trainee in the production department of Zamil Air Conditioners Company,
which is a part of Zamil Group. This report will be delivering some information related to my
work experience, acquired knowledge and also some of the very peculiar information about the
organization itself. As, most of the times I was just assigned to observe and note down some
operational work being conducted, I was also given an opportunity to gain some hands-on work
experience which will be further discussed in this report.
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Acknowledgment
First and foremost, I would like to express my gratitude towards Zamil Air
Conditionersfor giving me the opportunity to work alongside his team as an intern.
Secondly, I would like to thank Production Manager, Engr. Engr. Muhammad Al-
Raiyeswho has supervised me entirely during this whole period and introduced me in the whole
organization. He has been extremely supportive and gave me a lot of confidence since it was
my first time working in a professional environment and I always had a bit of a nervousness
that I may not be able to come parallel to their level of professional. However, it all went
extremely well since I had a lot of support and a boost of morale to give my best with all
sincerity.
Finally, I would like to express my sincere respect and gratitude to the Chair of
Mechanical Engineering Department, Dr. Faramarz Djavan Roodi who was very supportive in
giving timely advises and to guide me in what requirements to meet both at workplace and
university to have a great experience altogether.
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Table of Contents
Sr. # Content Page #

1. Abstract 1
2. Acknowledgement 2
3. Table of Contents 3
4. List of Figures 4
5. List of Tables 4
6. Introduction 5
7. Internship Organization 6
8. SWOT Analysis 8
9. Activities & Responsibilities 9
10. Major Tasks 11
11. Experience Gained 13
12. Conclusion 14
13. References 15
14. Appendix-I: First Technical Bi-Weekly Report 16
15. Appendix-II: Second Technical Bi-Weekly Report 20
16. Appendix-III: Third Technical Bi-Weekly Report 24
17. Appendix-IV: Student Feedback Form 28
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List of Figures
Sr. # Figures Page #

1. Figure 1: Inspection Machine 9
2. Figure 2: Tube Shop Process 11
3. Figure 3: Heat Exchanger Assembly 12
List of Tables
Sr. # Tables Page #

1. SWOT Analysis 8
2. Action Plan Form 10
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Introduction
As an undergraduate student of Mechanical Engineering at Prince Muhammad Bin
Fahd, the university requires from a student to attend an internship of 8 weeks (which is counted
as 3 credits in the degree completion apart from 136 credits) at any organization that is related
to the student’s major since it will help the students to learn more about their major and to also
know about how to utilize the studied courses in the practical and professional field of life.
Similarly, it was my time to get appointed as a trainee in an organization of my choice

which would be strictly involved in the Mechanical Perspective of Work because that is how I
would be able to grasp more knowledge and strengthen the already gained knowledge if I would
observe the theoretical aspects of it in real life practically. So, I was given an opportunity in
Zamil Air Conditioners, which is a part of Zamil Group. I was designated at their production
department where my supervisor and the production manager, Mr. Engr. Muhammad Al-
Raiyeshelped me and guided me into each department to help me gain experience and learn
about new things which will help me in the future when I work in the industry.
Since everything I have mentioned above is completely related to how I was managed
within the environment. But, if I put some light on the main objective of this internship program
that I was to attend and fulfil, there was a complete change of vibe. No matter how much
theoretical I have gained or will gain in the future, it will be of no proper advantage if I do not
nourish it and spend it while perform practical work. Because, a person who can work by his
own hands can never ever forget the idea or philosophy of that certain Job. Similarly,
personally, this internship experience was of a great deal to me and my overall practical skills.
Moreover, it gave me a field setup in such a manner from where I had to navigate my way
through by using the communication skills, leadership skills, technical skills, etc. which has all
been taught to me.
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Internship Organization
Founded in 1998 and headquartered in Dammam, Saudi Arabia, Zamil Industrial

Investment Company ('Zamil Industrial') is a premier business group engaged in the
development of innovative design and engineering solutions for use in the construction
industry. Also a leading manufacturer and fabricator of construction materials, Zamil Industrial
implements its engineering excellence through a wide range of products and services: pre-
engineered steel buildings, steel structures, air conditioning and climate control systems
designed for a wide range of commercial, industrial and residential applications, telecom and
transmission towers, process equipment, precast concrete building products, fiberglass and
rock wool insulations, pre-insulated pipes, maintenance and repair of HVAC equipment,
maintenance and inspection of industrial projects, building automation systems, security and
protection systems, turnkey project solutions, and solar power projects. The company also
offers award-winning installation and erection services.
Through its various industrial sectors, Zamil Industrial provides a broad range of products and
solutions that meet the increasing needs and requirements of the global building and
construction industry. Zamil Industrial employs more than 11,000 people in 55 countries and
derives about 25% of its revenues from outside Saudi Arabia. Zamil Industrial products are
sold in more than 90 countries around the globe, and the company operates manufacturing
facilities in Saudi Arabia, United Arab Emirates, Egypt, India, and Vietnam. Zamil
Industrial’s Steel Sector is represented by Zamil Steel Holding Company Ltd. Founded in
1977, Zamil Steel is a global leader in the manufacture of pre-engineered steel buildings and
the Middle East’s premier supplier of structural steel products and process equipment,
transmission and telecommunications towers, open web steel joists and roof and floor steel
decks. 6
Zamil Industrial’s HVAC Sector is represented by Zamil Air Conditioners Holding Co. Ltd.
Founded in 1974 as a pioneer in the Saudi Arabian air conditioning industry, the company has
expanded over the past four decades to become a leading international manufacturer of air
conditioning systems and is currently the number one producer of such systems in the Middle
East. Zamil Air Conditioners designs, manufactures, tests, markets and services a
comprehensive range of air conditioning products, from compact room air conditioners and
mini splits to large-scale central air conditioners, chillers and air-handling units for highly
specialized commercial and industrial applications.
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Zamil Industrial maintains a presence in the insulation sector through Gulf Insulation Group
(GIG), of which Zamil Industrial is managing partner and major shareholder, with 51% of the
equity. GIG comprises three companies: Arabian Fiberglass Insulation Co. Ltd. (AFICO),
Saudi Rock Wool Factory Company (SRWF) and Saudi Pre-Insulated Pipes Industries (SPPI).
These companies enjoy excellent reputations for the high quality of their environmentally
efficient insulation products and solutions, all of which conform to the highest international
standards.
This sector is represented by Rabiah & Nassar and Zamil Concrete Industries Co. Ltd. (Ranco
Zamil), in which Zamil Industrial has a 50% equity interest.
The Rabiah and Nassar Precast Concrete Factory (RANCO Precast) designs, manufactures and
erects precast concrete buildings used for various applications, including residential properties,
schools, shopping malls and industrial plants.
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SWOT Analysis
As engineers we were not only taught to do math and solve problems that occur related
to our field of specialization, we also have to perceive an organization from every perspective
of its strength, weakness, opportunities and threats because it is essential for its development.
So, below given is the SWOT analysis put forth after some delicate observations.
• Products availability globally on an international level.

Strength
• Around the clock service with quick delivery service.
• Our delivery team is not available from 12 AM to 8 AM.
Weakness
• Relatively low sales.
• A lot of demand on the international products that we have in the small

Opportunities
villages
• A new industry related to same business is due to open around the

Threats
facility in the near future.
Table # 1: SWOT Analysis
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Activities & Responsibilities
I was appointed as a trainee and an intern on the basis of the mechanical knowledge
which I have acquired so far and I was designated to work in the production department of
Zamil Air Conditioners where I was on a rotation basis training in almost every mechanical
related department that falls under the supervision of production department.
As far as the activities and responsibilities are concerned, they were to observe and
learn different manufacturing processes live and try them physically to get a perfect
understanding of how these processes work in the Fabrication shop. Where, there were several
Press Machines working on sheet metal and those machines had a capacity of 300 Tons of force
to bend the sheet into desired shape or cut it according to the design requirements. Moreover,
I was also able to participate in the coil shop and tube shop where they manufactured coils and
tubes for the condensers and evaporators of the air conditioning unit. Furthermore, I got the
chance to observe the control systems section in the production unit where they made a control
box and circuit to be used in powering and controlling Air Conditioning parameters. Since, the
factory was making A.C components, it also assembles them and which was a very prominent
and exciting place to be to see all the workers and technicians in almost perfect harmony.
Additionally, one of the very great aspects to observe and take part in was their quality control
and testing department where all the components especially the condensers and evaporators
were tested for any leaks as the coil and tubes may have a gap left after improper brazing
procedure.
Anyhow, there was an action plan form constructed by my team of supervisors who
were looking forward to train me according to the program they devised together. The action
plan form was followed to some extent but some tasks were given more focus and time than
the others.
Figure 1: Inspection Machine
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Time period Department/division
Task Supervisor responsible for
Task Name required for in which this work
# this training/work
this task will be performed
Company introduction, Production

1 4 hours Mr. Muhammad Al-Raiyes
Policy Department
Production
2 Coil and Tube Shop 1 week Mr. Muhammad Al-Raiyes
Department
• Fabrication Shop Production

3 • Slitting 2 weeks Mr. Muhammad Al-Raiyes
Department
• Paint line
Production
4 Mini Split Outdoor 0.5 week Mr. Muhammad Al-Raiyes
Department
Production
5 Mini Split Indoor 0.5 hours Mr. Muhammad Al-Raiyes
Department
Production
6 Scrap 1 Weeks Mr. Muhammad Al-Raiyes
Department
Production
7 Quality Control/Inspection 1 Weeks Mr. Muhammad Al-Raiyes
Department
Production
8 CTL & Maintenance 1 hours Mr. Muhammad Al-Raiyes
Department
Table # 2: Action Plan Form
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Major Tasks
Tube Shop:
It receives raw copper as inputs then it converts the raw material into product based on
needed for daily production. There are many CNC machines for the same applications with
different final parts sizes.
It has a lot of products and each product going to different department, some of the parts are
going to assembly line directly while others are needed to design bigger part Ex U tube goes to
coil shop to complete heat exchanger.
Figure 2: Tube Shop Process
Coil Shop:
In this department the heat exchangers are made following two steps first the assembly then
failure inspection. It is more complex than the tube shop because of the part are going to more
than one process and machine, also the inputs are a lot which makes understanding of the work
flow harder than other departments. In coil shop most of the operations need to involve human
hand there is nothing fully automated.
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Figure 3: Heat Exchanger Assembly
Finally, last part welded using brazing by operator hand. Before it was automated welding until
the department receive customer complaining due to leaking of coolant liquid then they decided
to change the operation from automatic to manual.
The inspection done by pumping liquid through the heat exchanger tube at high flow rate to
ensure that there is no leaking and to measure the maximum ability for the tube to stand the
high flow rate liquid.
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Experiences Gained
During the whole 8-week internship period there was a lot to learn and practice, both
in theoretical knowledge and practical knowledge. Since, I as a student really needed an
exposure towards the practical field of the theoretical gained knowledge. It really changed a a
lot of concepts which I didn’t believed in to an extent. The fact that once a person gains enough
knowledge and doesn’t really enhances it by practically putting into use, he has no benefit of
that earned knowledge. Similarly, whatever I had learned throughout my university career so
far, had no meaning until I put it to use in my daily life, professional life, technical life and
many related areas. Because, it is well said that If a person spends knowledge on someone or
somewhere, he gains more in return of that expenditure. Whatever I practiced and whatever I
learned during this whole internship tenure proved extremely beneficial for myself.
First of all, communication skills hold a very important place in a work environment
among personnel where effective communication can produce some really positive outcome.
Giving a proposal of a project, educating technically and orally about a persistent problem
occurring during operations, professionally following the code of conduct in the premises of
the operation zone, etc. all of these gave me a jump start towards building my reputation as a
member of the organizations team and producing effective results wherever possible.
Second of all, having a proper background knowledge related to the field of work,
mechanical, in my case, really helps a person to better understand the new concept and new
procedures of work which were taught to me to ensure successful training of my devised
program. Moreover, at times there were opportunities where there was a need of leadership
skills to successfully manage the team of labours and officers to execute a certain type of Job
in need of emergency situations, gave me an overview of what tactics to adopt and how to
handle pressure in such situations. But, one thing was pretty clear that both man and machine
have opposite attributes but they both need to be handled the same way.
So, in my opinion, the whole experience went satisfactory. There were some ups and
downs during my whole tenure but I did try my very best to satisfy my supervisors and myself
that I’m putting effort to learn and advance in future so I can benefit from these opportunities.
It also provided a very deep understanding of the atmosphere where there are many types of
people and understanding each of them and handling them accordingly proves to be very
healthy for the organization and oneself.
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Conclusion
To sum up, the whole internship program is a must to attend at any organization which
is related to the student’s major as this is included in the degree program which is worth 3
credit hours. An 8-week tenure is demanded from the university in which the student undergoes
all the types of training necessary by the organization in which he is working, which gives an
opportunity to work side by side by the employees over there and obtain a hands-on experience.
Most of time, there will be an environment or a designation that would be related to

someone’s major but doesn’t necessarily means that he or she will have to expert in every
branch of studies. The job or training is focused into one specialization and the training also
follows such protocols. However, in some organizations there is a very good chance that we
can expose ourselves to several operations or work that we have studied theoretically about.
Because it really gives a very good feedback in terms of us learning from observing certain
phenomena in-person and strengthens our concept accordingly.
As a Mechanical Engineer, there is always a need to practical exposure towards all the
possible mechanical aspects of the industry since it can be very helpful to understand the future
possibilities of an industry and their workplace along with the work environment. In the end, I
would just like to thank all the supervisors who helped me and educated me to learn and put
into use the knowledge of engineering in a mechanical perspective.
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References
1. Zamil Industrial (2019). About Us. Retrieved from:

https://www.zamilindustrial.com/
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APPENDIX-I: First Technical Bi-Weekly Report

First Bi-Weekly Technical Report

At:
Reporting Period 9th June, 2019 to 20th June, 2019

SUMMER – 2019
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Summary
As a part of university’s requirement, I was given an opportunity to be able to train at the Zamil
Air Conditioners Factor and Facility in Dammam 2nd Industrial Area where I was able to get
experience in their manufacturing department of air conditioners and its components. This
program will further help me in future in order to get a job and also improve my knowledge
and skills that I have gained from courses attended at university.
Background
This first couple of weeks of training program was intended to be done in the
manufacturing departments which specializes in manufacturing of coils and tubing that
eventually become a part of the evaporator in air conditioners. Moreover, I would be guided
about their safety policies and further information about using equipment and machines.
Additional Information:
Starting Day of Training 09th June, 2019

Zamil Air Conditioners, Coil Shop and Tube
Company Name and Training Site
Shop.
Supervisor Name Engr. Muhammad Al-Raiyes
Company’s Training Schedule From 09th June, 2019 to 20th June, 2019
Progress
The following progress is given in days per week to follow the tasks easily and to have a brief
information related to activities and responsibilities I was in;
• Day # 1 (Sunday): The first day at the factory was very looking very promising as I was
introduced to different number of major departments and their managers and also I was able
to get involved in their safety program which is held every week to go over the required
rules to follow while working and avoid getting injured in any accident.
• Day # 2 (Monday): During this day, I was given an action plan form which is required to
list all the tasks and department I will be working in and also to have a good plan to follow
relevant to my field of study. This tasks and departments were selected by my supervisor.
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• Day # 3 (Tuesday): On this day, I was able to begin and join the coil shop for air
conditioners where they assemble and bent and shape the copper coils into desired shape to
be placed in an evaporator and condenser. (Appendix 1)
• Day # 4 (Wednesday): This day I was able to start with the process where I was first taught
how to use the fin press machine in order to perform fin dropping.
• Day # 5 (Thursday): Similarly, I was still in the coil shop with the supervision of production
manager. I was able to use the expander which expands the tube.
• Day # 6 (Sunday): On the second week of training, I was able to move in to the tube shop
for further learning and experience after the coil shop.
• Day # 7 (Monday): While being in the tube shop, I was educated about the different types
of CNC machines used there to manufacture and shape the tubing. Moreover, since these
tubes are prepared with extreme precision and dimensions, they require CAM (Computer
aided Manufacturing) codes to be first used.
• Day # 8 (Tuesday): I was taught about the Chiyoda CNC machine where I was able to
perform tube shaping.
• Day # 9 (Wednesday): This day, I was progressed to the other machine called Silver CNC
which performs operations like bending the tubing so it can be gone in the heat exchanger
or condenser.
• Day # 10 (Thursday): The last day of second week, I was able to move to the drilling
machines which drill holes in the tubing or tube for a certain purpose.
Plan
1. Fabrication Shop, paint line and slitting departments.

2. Mini Split unit for outdoors.
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Appendix
Condenser with coils and tubing
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APPENDIX-II: Second Technical Bi-Weekly Report

Second Bi-Weekly Technical Report

At:
Reporting Period 23rd June, 2019 to 4th July, 2019

SUMMER – 2019
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Summary
Background
After spending the first couple of weeks into the coil and tube shops of the
manufacturing section of the Zamil Company, I was able to move and progress in to the
Fabrication shop, paint line, slitting and mini split outdoor units. These departments will give
me a new experience in learning about the different types of skills and procedures to perform.
Starting Day of Training 23rd June, 2019

Zamil Air Conditioners, Fabrication shop,
paint line, slitting and mini split outdoor
Company’s Training Schedule From 23rd June, 2019 to 4th July, 2019
Progress
• Day # 11 (Sunday): The first day of third week started with a short safety meeting, and I
was told to report in the fabrication unit where I will learn different fabrication processes
especially performed on sheet metal.
• Day # 12 (Monday): The second day I was able to observe at different types of press
machines which performed some bending and cutting on sheet metal. This was solely done
with a 300 Ton press machine easily capable of performing such activities.
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• Day # 13 (Tuesday): On this day, As still being within the fabrication department, I was
able to understand and learn the process of brazing. Brazing was being done on the coils of
the heat exchanger which is usually placed in the mini split outdoor unit.
• Day # 14 (Wednesday): The process of brazing was continued till the next day and since
brazing uses heat range less than welding and more than soldering, it was a very exciting
and interesting process to watch at since the metals used in the tubes are not having high
melting point.
• Day # 15 (Thursday): At the last day of third week, I was given information about shaping
and developing the control box. This control box is shaped from a sheet metal press and
bending machine.
• Day # 16 (Sunday): On this day, I was able to observe the operation of putting together the
control box with all the wiring loom and knobs and buttons for the A/C. It was a very tiring
job since each wire has to be placed and connected and placed properly.
• Day # 7 (Monday): In the fabrication department, after the whole process was finished to
completing the control panel. I was able to observe the bending process on a sheet metal in
order to form mounts for the split outdoor unit.
• Day # 8 (Tuesday): I continued with the fabrication unit learning about how to perform
bending operations on sheet metal and what parameters to adjust if required to get the
desired results.
• Day # 9 (Wednesday): I finally got the chance to operate the press after dictation of
technicians and it helped me to successfully perform a bending operation on the sheet metal
for motor mount.
• Day # 10 (Thursday): The last day of week four and completion of a month, which means
half of the internship program has been completed, I was able to return to the coil shop to
further see the coil shaping and cutting for the heat exchanger units.
Plan
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3. Fabrication Shop for spot welding operations.
4. Quality checking in the heat exchanger tubings.
Appendix
Brazed Tubing on top of heat exchanger
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APPENDIX-III: Third Technical Bi-Weekly Report

Third Bi-Weekly Technical Report

At:
Reporting Period 7th July, 2019 to 18th July, 2019

SUMMER – 2019
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Summary
Background
The half of the internship has been finished, where I have attended the fabrication shop to
observe and learn the different process.
Starting Day of Training 7th July, 2019

Zamil Air Conditioners, Fabrication shop,
paint line, slitting and mini split outdoor
Company’s Training Schedule From 7th July, 2019 to 18th July, 2019
Progress
• Day # 21 (Sunday): The first day of the fifith week began with a good plan ahead of me.
Since, after experiencing and learning about most of the processes. I was able to move in to
the welding section where the welders and some automated machines perform spot welding
on the components of the frame of the A/C and the metal components.
• Day # 22 (Monday): This day also I was involved in the welding department where I was
learning about the parameters to spot weld the different metals of thickness together.
• Day # 23 (Tuesday): After I was done with the whole fabrication department where I gained
a lot of work-related experience as well as the experience where I was able to communicate
professionally and technically. I was then due for moving into the assembly zone.
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• Day # 24 (Wednesday): The assembly zone performed assemblies in putting together all
the different components of an indoor and outdoor split unit. This area had some very trained
and quick workers as they knew which part goes where and for that I had to maintain
distance and observe them very carefully.
• Day # 25 (Thursday): While being at the assembly area, the best thing I learnt and
experienced was the amount of coordination between each worker and technician and they
exactly knew what to do and how production to end with within a prescribed amount of
time.
• Day # 26 (Sunday): The sixth week began and I was to attend a safety meeting. We were
given awareness of the safety rules to follow and I was order to move into the quality or
testing department.
• Day # 27 (Monday): In the quality department, I observed a lot of heat exchangers for
outdoor unit of splits and each of them were tested and inspected manually by a quality
control technician.
• Day # 28 (Tuesday): This day I observed that there was an automated sector as well for
testing all of these tubing and flowlines properly by automated machines to detect any leaks
if available.
• Day # 29 (Wednesday): Then I was able to perform and see the extent to which these heat
exchangers are testing before going to the markets and all the way end-users who are
customers. They have a log of each data from the tested heat exchangers which explains the
amount of satisfaction or quality of the product.
• Day # 30 (Thursday): The last day of the sixth week, I was finally able to gather some
handful amount of data for other related things like machines, instrument and equipments
and I was also informed about the principle with which the A/C works directly related to
thermodynamics and HVAC.
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Plan
5. Maintenance department for the repair of some A/C components or even new defective
pieces.
6. In the scrap yard to manage and dispose unnecessary components and parts for recycling.
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APPENDIX-IV: Student Feedback Form
Please fill in the form carefully and ensure that it is attached at the back of your Final Technical
Report before uploading onto the Blackboard for your Advisor to grade.
Name of Student: Faisal Al-Shamrani

Student ID: 201303531
Department: Civil/Electrical/Mechanical
Period of internship: 9th June, 2019 to 25th July, 2019

Company Name: Zamil Air Conditioners
Department student Production Department
was attached to:
Describe briefly your work experience:
Was nature of work assigned challenging? Yes/No

Was your work environment satisfactory? Yes/No
Was the work technical in nature? Yes/No
Were you treated as a member of a professional team? Yes/No
Were you able to learn from others? Yes/No
Were you able to talk to your supervisor when needed? Yes/No
Would you recommend that we continue to assign students
Yes/No
to this company in future?
Would you work for this company after graduation? Yes/No
Overall, how do you rate the company in providing you

Excellent / Good / Satisfactory/Poor
with this training?
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What new knowledge or skill have you acquired as a result of this internship?
Which courses, if any, have helped you in learning the new knowledge, skills and technologies needed
to do your work?
What would have better prepared you forth is semester's work?
Suggest ways in which you think the Internship Program, as a whole can be improved:
Date:
Signature of Student:
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