A TECHNICAL REPORT ON

STUDENT INDUSTRIAL WORK EXPERIENCE

SCHEME (S.I.W.E.S)

UNDERTAKEN AT

AKWA IBOM STATE MINISTRY OF WORKS AND FIRE

SERVICE
UDOUDOMA AVENUE, UYO.

BY

SAMPSON IDONGESIT MONDAY

18/EG/ME/1221
DEPARTMENT OF MECHANICAL ENGINEERING
FACULTY OF ENGINEERING
UNIVERSITY OF UYO

SUBMITTED TO

THE SIWES CORODINATOR

DR. ANIEKAN OKON
MECHANICAL AND AERPSPACE ENGINEERING
FACULTY OF ENGINEERING

FROM

MAY 21ST TO OCTOBER 6TH 2023

 A TECHNICAL REPORT ON

STUDENT INDUSTRIAL WORK EXPERIENCE

SCHEME (S.I.W.E.S)

UNDERTAKEN AT

AKWA IBOM STATE MINISTRY OF WORKS AND FIRE

SERVICE
UDOUDOMA AVENUE, UYO.

BY

SAMPSON IDONGESIT MONDAY

018/EG/ME/1221
DEPARTMENT OF MECHANICAL ENGINEERING
FACULTY OF ENGINEERING
UNIVERSITY OF UYO

SUBMITTED IN PARTIAL FULFILMENT OF THE AWARD OF

BACHELOR OF ENGINEERING (B.ENG) IN
MECHANICAL ENGINEERING

FROM

MAY15TH TO OCTOBER 6TH 2023

 DECLARATION

I, SAMPSON IDONGESIT MONDAY, hereby declare that this Internship report is the
result of my original piece of industrial attachment work conducted between May 16 th to
October 6th 2023; under the supervision of Engr. Oto-Obong Umoren, who is the head of
mechanical engineering section, Uyo. In instances where references of other works have
been cited, full acknowledgement has been given. This work has never been submitted in
whole or in part in any institution for any award.

________________________
SAMPSON IDONGESIT MONDAY
018/EG/ME/1221
Department of Mechanical and Aerospace Engineering
University of Uyo.
Akwa Ibom State, Nigeria.
 CERTIFICATION

This is to certify that this technical report was written by SAMPSON IDONGESIT MONDAY
with matriculation number 18/EG/ME/1221 of Department of Mechanical and Aerospace
Engineering in the Faculty of Engineering, University of Uyo, Akwa Ibom State. The report
meets the requirement for the degree of Bachelor of Engineering (B.Eng) in Mechanical
Engineering. The work embodied in this report has not been submitted in part or in full for any
other diploma or degree of this or any other institution.

__________________ ________________
SAMPSON IDONGESIT MONDAY
18/EG/ME/1221 Date
(Student)

__________________ _________________
Dr. ANIEKAN OKON Date
(SIWES Coordinator)
 DEDICATION

I dedicate this report to God Almighty, who saw me through the period of my SIWES training
program and ordered my steps all the way. I also dedicate this report to my family.
 ACKNOWLEDGEMENT

My sincere gratitude goes to the Almighty God for His love, mercy, favour and protection upon
me throughout the period of my Industrial Training. My unreserved gratitude goes to Mr. and
Mrs. Monday Sampson for their parental, moral and financial support. Thank you for raising a
world leader. I am greatly indebted to my siblings Eyakeno-Obong, Paul and Miracle. I thank
you all for your moral, spiritual and financial support.

I want to say a big thank you to my industrial based supervisor, Engr. Oto-Obong Umoren and
the technician in my unit, Mr, Augustine, Mr. Cabal who helped with solutions to my numerous
questions. I am grateful to the technicians in the mechanical section for providing with the
opportunity to be exposed to engineering services to the automobile industry. I also want to
thank my mother she encouraged me all through my Industrial Training period and also
appreciate my uncle and dad for their effort to ensure I get a placement, also for their moral and
financial support.

Finally to my Institution based supervisor Engr. Aniekan Okon for his advice and support, to my
other friends and colleague like Emmanuel, Sandy, Ubong, Victor etc. I say thank you all.

I am highly grateful.
TABLE OF CONTENT
 ABSTRACT

This report presents the experiences I acquired during my 6 months of industrial training
undertaken at Akwa Ibom State Ministry of Works and Fire Service, UYo.
My training was on the diagnosis, repairs, maintenance in AC and Refrigeration and automobile
vehicles ranging from cars, SUVs, light trucks and pick-ups. During this period, I acquired
practical knowledge on how to repair, replace and install some mechanical parts and systems
also assisted in providing the units the functionality they need. This report discusses the technical
skills gained during the training period and justifying the relevance of the scheme in equipping
students with needed technical competence to thrive in the real world.
 CHAPTER 1

INTRODUCTION

Training is an integral part of vocational or career development which is fast becoming a global
and pervasive phenomenon in any establishment, the absence of which spells doom for such an
institution and the presence of which determines the success of any enterprise or company. In
another view, training is an organized, coordinated development of knowledge, skills and
attitudes needed by an industrial worker to master a given situation or perform a certain task
within an organization setting which might be needful in future time. It was observed that
effective training brings about an increase in knowledge required in the job, knowledge of the
structure and institution/business arms of the organization.

1.1 What is SIWES?

The Student's Industrial Work Experience Scheme (SIWES) is an intensive training scheme that
is aimed at exposing the prospective Nigerian graduate to the practical aspects of his or her
course of study and in a broader context his or her profession. Ideally it is a six (6) month long
program, covering the span of 24 weeks and should expose the student to a wide range of
practical skills and techniques relevant to his field of study. One of its many objectives is to
make the transition from school to the world of work easier and enhance student’s contacts for
later job placement and also to enlist and strengthen employer’s involvement in the entire
educational process and prepare students for employment in industry and commerce. Students
are therefore exposed to skilled labour pertaining to their field of study and are able to bridge the
gap between what is taught theoretically in the classroom and what is applicable in the industry.

In October 1971, the federal government established the Industrial Training Fund (ITF). In its
policy statement no. 1 published in 1973, a clause was inserted dealing with the issue of practical
skills among the locally trained professionals in the tertiary institutions. Section 15 of the policy
statements states clearly that “Great emphasis will be placed on assisting certain products of the
postsecondary school system to adapt or orientate easily to their possible post graduate job
environments” which subsequently led to what is known as Students Industrial Work Experience
Scheme. "Before the scheme was established, there was a growing concern among industrialists
that graduates of our institutions of higher learning lacked adequate practical background studies
preparatory for employment in industries and other organizations. Thus, the employers of labour
were of the opinion that the theoretical education going on in higher institutions was not
responsive to their needs.

The SIWES was launched in 1973 as a program designed to impart the undergraduates of the
nation’s tertiary institutions studying professional courses with the practical methods of
performing professional functions to real life situations on site, in the office or even the factory
and how they apply themselves mentally, intellectually and physically in relation to what they
have been thought in the classrooms theoretically. It works with the following professional
bodies to function effectively across the tertiary institutions nationwide. These are the Nigeria
University commission (N.U.C.), National Board for Technical Education (N.B.T.E.) and the
National Commission for Colleges of Education (N.C.C.E.). Thus, equipping the students with
the necessary skills and technical knowledge to make them highly competitive and professional
individuals in the labour market.

1.2 AIMS AND OBJECTIVES OF SIWES

The main objectives of the scheme are:

1. To provide an avenue for students in institutions of higher learning to acquire

industrial skills and experience in their course of study.
2. To prepare students for the industrial work situation they are to meet after graduation.
3. To expose students to work methods and techniques in handling equipment and
machinery that may not be available in their institutions.
4. To make the transition from school to the world of work easier, and enhance student’s
contacts for later job placement.
5. To provide students with an opportunity to apply their knowledge in real work
situations, thereby bridging the gap between theory and practice.
6. To enlist and strengthen employer’s involvement in the entire educational process and
prepare students for employment in industry and commerce.
1.3 IMPORTANCE OF SIWES

SIWES has a lot of importance amongst which are:

1. It exposes students to real life situation, thus supplementing the theoretical lesson.
2. It helps to improve the quality of skilled man power of the students.
3. It gives students practical knowledge of course of study.
4. It provides a forum for industries to evaluate prospective employers and gives
feedback to institutions.
5. It establishes a close collaboration between institutions and industries, factor which is
essential for preparing student for the workforce.

1.4 ORGANIZATIONS INVOLVED IN THE MANAGEMENT OF SIWES

PROGRAM AND THEIR ROLES

The organizational structure for the SIWES program is as follows:

1. The Federal Government

2. The Industrial Training Fund

3. The Coordinating Agency (NUC)

4. The Institutions (Universities)

5. The Employers

6. The Students

1.4.1THE FEDERAL GOVERNMENT:

1. To provide adequate funds to the I.T.F through the Federal Ministry of Trade and
Investment.
2. To make it mandatory for all ministries, companies and parastatals; to offer places for
the attachment of students under Decree No.47 of 1971, as amended in 2011.

1.4.2 THE INDUSTRIAL TRAINING FUND:

1. Provide logistics and materials necessary for effective administration of the schemes,
 Such documents as: I.T. Form8, S.C.A.F and D.E.P.F.

2. Ensure the visitation of I.T.F officers to the supervising agencies, institutions,

employers, and students on attachment.
3. Provide information on companies for attachment and assist in the industrial
placement of students.
4. Continuously review and carry out research into the operations of the program.
5. Vet and process student’s log books and forms.

1.4.3 THE SUPERVISING AGENCY (NUC):

1. Develop, monitor and review job-specifications in collaboration with the institutions

towards the maintenance of national minimum academic standard for all programs
approved for SIWES.
2. Liaise with I.T.F and takes part in the biennial national conference and other relevant
seminars, conferences, workshops and meetings.
3. Research into the development of the program in line with advances in technological
development.

1.4 BENEFITS OF INDUSTRIAL TRAINING

The major benefits accruing to students who participate conscientiously in industrial training
include the following:

1. Opportunity for students to blend theoretical knowledge acquired in the classroom

with hands-on practical application of knowledge required to perform work in
industry.

2. Exposure of students to the environment in which they will eventually work,

thereby enabling them to see how their future professions are organized in
practice.

3. Preparing students to contribute to the productivity of their employers and

national development immediately after graduation.
 4. Provision of enabling environment where students can develop and enhance
personal attributes such as critical thinking, creativity, initiative, resourcefulness,
leadership, time management, presentation skills and interpersonal skills, amongst
others.

5. Enabling students bridge the gap between the knowledge acquired in institutions
and the relevant production skills required in work organizations.

6. Enabling students appreciate the connection between their courses of study and
other disciplines in the production of goods and services.

1.5 PROBLEMS OF SIWES

This scheme like any other is faced with certain challenges which include:

1. Inability to provide good supervision for those on the Industrial Training Fund (ITF).

2. Inadequate funding for the training.

3. Inabilities of the office to find and place student in an establishment that will help student
gain the technical know-how.
 CHAPTER 2

THE AKWA-IBOM STATE MINISTRY OF WORKS AND FIRE SERVICE

2.1 BRIEF HISTORY AND SERVICES

Subsequent to the creation of Akwa-Ibom State, once part of the old Cross-River state, on the
twenty third day of September, nineteen eighty seven (1987), as any state would, various
ministries were established with Akwa-Ibom state ministry of works (then ministry of works and
transport) being one of them. At present it is officially known as not just ministry of works but as
the ministry of works and fire service. "The Akwa Ibom State Ministry of Works is the state
government ministry charged with the responsibility of planning, devising, and implementing
state policies on public works."[2]

The commissioner on seat is by name Professor Eno James Ibanga who is a former vice
chancellor of the Akwa-Ibom state university (AKSU) while the director of the mechanical
engineering directorate is Engr Anietie Nsen.

Under the department of mechanical engineering to which I was posted, there are three sub
sections; operations, central mechanical workshop and the monitoring sections. Under this sub
sections are four units which are; the plant unit, vehicles unit, plumbing and air-conditioning unit
with the welding and fabrication unit as the last unit. Faulty vehicles both of staff and outsiders
are brought for servicing and repairs in the vehicles unit which is supervised by a designated
manager for a given period. This unit is facilitated with a number of high grade tools and
machinery uncommon to many automobile repair shops in the state. The Air-conditioning unit at
the time of my attachment was under the supervision of Mr Aniefiok Inyang; a former student of
this department whiles the welding and fabrications unit was manned by Mr Anietie Brownson
who also was the store keeper. As at the time of my attachment, there was no staff assigned to
the plant unit which consists of heavy duty diesel generators. I came to discover by inquiry that
the men assigned to that unit were paid off and the unit disbanded temporarily.

The official headquarters of the agency was located at the State Government Secretariat Annex,
Uyo. At the moment the ministry is permanently located at the Dakkada Secretariat complex
located at Sir Udo Udoma Avenue, just by the Oron road Udo Udoma traffic light. The
establishment structure and organizational structure is hereby attached.
2.2 VISION:

To plan, develop and evolve lasting infrastructural facilities such as Roads, Bridges, Electricity,
Workshop establishment and maintenance/repairs of heavy Duty equipment and Fire service to
enhance and sustain social-economic growth of the State.

2.3 MISSION STATEMENT:

To harness available resources, human and material for the planned development and
maintenance of Road Network, Electrical Infrastructure, heavy Duty equipment, as well as,
functional Fire Service system for effective service delivery in the service.

In summary, the Ministry of Works is focused on the attainment and sustenance of adequate
infrastructural development in the state for socio- economic development in the state.
 CHAPTER 3

WORK EXPERIENCE

3.1 SAFETY RULES IN THE WORKSHOP

Just as any workplace has norms and ethics, I was introduced to the workshop's safety guidelines
on my arrival there while also being given a tour of the workshop on my arrival and first day of
attachment. Some of the safety guidelines are as follows:

(i) Always make use of a safety boot.

(ii) Use the right tool for the right job.
(iii) Make use of eye goggles where necessary.
(iv) Tools must not be placed anyhow in the toolbox.
(v) Keep the shop tidy before any operation.
(vi) Do not use worn out spanners, any broken tool should be reported to the instructor.
(vii) Tools should be in the box when not in use.
(viii) Do not wear loose apron or sleeve.
(ix) Do not touch any machine tool until you are told to do so.
(x) Get help when lifting and cutting heavy materials.
(xi) Do not use hammers with loose head or split handle.
(xii) Be sure all guards are in place before attempting to operate the machine.
(xiii) Dress appropriately: Remove neckties, sweater, wristwatch, and jewelry while working
on the lathe.
(xiv) Do not use your hand to remove the chips.
(xv) Clean oil and grease from the floor of working area as soon as possible in the case of
spillage.
(xvi) Playing and fighting are prohibited in the workshop.

3.3 AUTOMOBILE REPAIRS AND MAINTENANCE.

Automobile engineering encompasses different sections from electrical section to the vulcanizing
section to the panel beating and most importantly the core mechanical section with the air
conditioning/ventilation unit not left out. This section will extensively explain in detail what was
learnt in the mechanical section and will highlight briefly the vulcanizing section.

3.3.1 Mechanical section

The main focus of the mechanic in an automobile is the engine itself. However other sections/
systems where his expertise is needed is in the transmission unit(which the wheel, brake, axles
and transmission shafts form a part), suspension system, fuel system, steering and braking
system.

This section is the crux of any automobile system. Majority of the problems which lead to the
improper firing and operation of the car are traceable to this section. During the duration of my
attachment I was exposed not just to practical skills but even theoretical information. I was given
a hand book which helped me to better understand certain things that pertain to automobiles.
During the program automobile parts were identified, the automobile system they belonged too
and how they affect the overall running of the vehicle. A good understanding of the parts and
their various systems makes troubleshooting a lot easier.

(a) The cooling system: A typical automotive cooling system comprises of a series of channels
cast into the engine block and cylinder head, surrounding the combustion chambers with
circulating water or other coolant to carry away excessive heat, radiator, consisting of many
small tubes equipped with a honeycomb of fins to radiate heat [5]. The major components of the
cooling system are the water pump, freeze plugs, the thermostat, the radiator, cooling fans, the
heater core, the pressure cap, the overflow tank and the hoses [6]. Cooling systems can make use
of air or water as fluids. But water is more prominently used than the latter. An anti-freeze
(glycol) is used in the production of coolants which prevents the water from drying up quickly
and helps to maintain the engine and suitable temperatures. The absence of a cooling system can
lead to over heating and hence rapid wear and tear of the engine. A number of parts which make
up this system are shown below.
 (b) Water Pump
(a) Thermostat

(c) Detailed illustration of a radiator. (d) Radiator

 (e) Detailed illustration of a cooling system

Figure 3.2: Cooling System Diagrams/pictures

(b) Charging System: The charging system keeps a charge in your battery and provides
electrical energy for the radio, lights and other features while the car is running. The modern
charging system consists of the alternator, battery, wiring and electronic control unit (ECU) [7].
The charging system generates electrical current for the lights, the radio, the heater, the engines
electrical systems, and other electrical accessories. It also maintains the batteries in a charged
state, recharging them as necessary [8]. The three main components of this system are: the
alternator, the voltage regulator, and the batteries. Other components are the fuse and fuse links,
charging wire, ignition switch and charging warning lights (CHG lights).
 Figure 3.3: Illustration of a charging system

(c) Lubrication System: This is an automobile system that directs and circulates the flow of oil
in the engine. It aids in the lubrication of moving parts within the engine so that the engine is not
subject to wear and tear. Most automobile engines use SAE 40 engine oil as this is the grade of
oil most suitable for automobile engines. Most engines displace four(4) liters of oil while few
displace up to five(5) liters. (SAE stands for Society of Automotive Engineering founded in 1905
by Andrew Ticker and Henry Ford). The lubrication system consists of the oil filter, oil pump,
oil screen/oil pick up tube, the oil galleries, oil switch and oil pan/engine sump. A faulty
lubrication system will can result to serious damage on the engine which also implies engine
overhaul or procurement of
an entirely new one where
repairs are impossible.

(a) An oil pump for Toyota vehicles (b) An oil pump (top view)
 (c) Layout of a Lubrication System

(d) Transmission System: Transmission system in a car helps to transmit mechanical power
from the car engine to give kinetic energy to the wheels. It is an interconnected system of gears,
shafts, and other electrical gadgets that form a bridge to transfer power and energy from the
engine to the wheels. The complete setup of the system helps to maintain the cruising speed of
the car without any disturbance to the car’s performance. The oldest variant of the transmission
system is the manual transmission that has undergone various modifications and alterations to
form the present day automatic transmission. Most modern gearboxes are used to increase torque
while reducing the speed of a prime mover output shaft (e.g. a motor crankshaft). This means
that the output shaft of a gearbox will rotate at slower rate than the input shaft, and this reduction
in speed will produce a mechanical advantage, causing an increase in torque. The major parts of
this system are the gearbox, the axles and half shafts, the propeller shafts, the road wheels and
the car tyres, the clutch and the differential. Without the transmission system, power and motion
cannot be transferred from the engine to the wheels and movement would not be possible.
(a) Manual transmission system. (b)Clutch plate assembly

(c) Transmission half shaft.

(d) Torque converter

Figure 3.5: Illustrations for

Transmission system

(e) Suspension System: Suspension is the term given

to the system of springs, shock absorbers and linkages
that connects a vehicle to its wheels. Suspension
systems serve a dual purpose — contributing to the car's road holding/handling and braking for
good active safety and driving pleasure, and keeping vehicle occupants comfortable and
reasonably well isolated from road noise, bumps, and vibrations, etc. The suspension connects
the vehicle’s body to the ground, so all forces and moments between the two go through the
suspension system. Thus, the suspension system directly influences a vehicle’s dynamic
behavior. The suspension system performs the following functions:

• Road Holding: The forces on the contact point between a wheel and the road act on the
vehicle body through the suspension system. The amount and direction of the forces
 determine the vehicle’s behavior and performances, therefore one of the important tasks of
the suspension system is road holding.
• Handling: A good suspension system ensures that the vehicle will be stable in every
maneuver. However, perfect handling is more than stability. The vehicle should respond
to the driver’s inputs proportionally while smoothly following his/her
steering/braking/accelerating commands. The vehicle behavior must be predictable, and
behavioral information should accordingly be communicated to the driver.
 To restrict road vibrations from being transmitted to the various components of the
vehicle, to protect the passengers from road shocks, to maintain the stability of the
vehicle in pitching and rolling.[9]

The main parts of the suspension system are:

i. Control Arm: A movable lever that fastens the steering knuckle to the frame of the
vehicle.
ii. Control Arm Bushing: This is a sleeve which allows the control arm to move up and
down on the frame.
iii. Strut Rod: Prevents the control arm from swinging forward and backwards.
iv. Ball Joints: A joint that
allows the control
arm and steering
knuckle to move
up and down and
sideways as well.
v. Shock absorbers or
Struts: prevents the
suspension from
bounce after spring compression and extension.
vi. Stabilizer Bar: Limits body roll of the vehicle during cornering.
vii. Spring: Supports the weight of the vehicle.
 (a) Suspension
system arrangement

(b) Suspension components of a vehicle wheel

Figure 3.6: Illustrations for suspension system

(f) Electrical System: The electrical system's main function is to generate, store and supply the
electric current to various systems of a vehicle. It operates the electrical components/parts in
vehicles. These components include several electrical gauges, digital gadgets, power windows,
central locking mechanisms, and many more [10]. The battery, alternator, and starter are the
three main parts of any vehicle's electrical system; all three of these parts work together to start a
car and keep it running. The starter and the alternator specifically draw power from the battery to
start the engine [11].
 Figure 3.7: A Vehicle's Electrical system.

(g) Braking System: Braking is the mechanism in the motor vehicle which is used to decrease
the acceleration of a vehicle when required. A brake on the other hand is a device that an
artificial resistance is applied on to a moving machine member in order to retard or stop the
motion of the member or machine. Braking of a vehicle depends upon the static function that
acts between tyres and road surface. Brakes work on the following principle to stop the vehicle:
“The kinetic energy due to motion of the vehicle is dissipated in the form of heat energy due to
friction between moving parts (wheel or wheel drum) and stationary parts of vehicle (brake
shoes)”. The heat energy so generated due to application of brakes is dissipated into air. Brakes
operate most effectively when they are applied in a manner so that wheels do not lock
completely but continue to roll without slipping on the surface of road”[12]. The components of
a braking system include; the master cylinder, the ABS (Anti-Lock Braking System), Servo
mechanism, brake pad, brake disc etc.
(a) Complete Brake system (b) brake disc and caliper arrangement

Figure 3.7: Hydraulic Braking System

(h) Fuel System: A vehicle's fuel system is responsible for the circulation of fuel be it petrol,
diesel or even very recently gas around the parts of the engine where it is needed, most often the
piston and cylinders where combustion takes place. "The function of the vehicle fuel system is to
store and supply fuel to the engine. The engine intake system is where the fuel is mixed with air,
atomized, and vaporized and burned to produce energy. The fuel is stored in the fuel tank and the
fuel pump draws fuel from the tank. The fuel system is made up of the fuel tank, pump, filter,
and injectors or carburetor, and is responsible for delivering fuel to the engine as needed. Each
component must perform flawlessly to achieve optimum performance and reliability [13].
 Figure 3.8: An Illustration of a fuel system.

(i) Steering System: "The steering system in a vehicle is used to move the vehicle in a
particular direction. This is a very important sub-system in a car without which it would be
impossible for a vehicle to follow its desired path. The steering system can be used to steer all
kinds of vehicles like cars, trucks, buses, trains, tanks etc. The conventional steering system
consisted of turning the front wheels in the desired direction. But now we have four wheel
steering system mostly used in heavy vehicles, to reduce the turning radius, rear wheel steering
system, differential steering system etc.

The basic components of any steering system are: steering column, steering box/rack, tie rods
and steering arms. The main geometry followed in steering is ACKERMANN STEERING
GEOMETRY. It shows that while negotiating a curve, the inner wheel needs to follow a smaller
path as compared to the outer wheel. This results in different steering angles for the respective
tires."[14]

A very vital part of an automobile though not a system on its own is the power unit which
comprises of the engine solely to generate power for motion.
 Figure 3.9: Steering system illustrations

3.3.1.2 How
to troubleshoot
a faulty
vehicle

When any
vehicle is
brought for
repairs, a
number of
steps are
followed to
diagnose the problem and proffer solution. They are as follows

 Safety kits must be used and all safety guidelines must be put to consideration.
  Inspection of the vehicle for leakage or any other abnormalities which can aid in
pinpointing the problem of the vehicle.
 Check the water level in the vehicle's radiator and then the oil level before the hydraulic
level.
 Ask questions and listen to the vehicle owner.
 Drive the car for a reasonable distance before coming to a suitable conclusion with
regards to the system that is faulty and offer solutions to the problem.
 Carry out the necessary work on the vehicle.
 Test run the vehicle for confirmation before delivering it to the client.

 With the aid of the bar and adjusting your free hand on the tyre surface, simultaneously
rotate the tyre while putting the bar in the necessary position to get it out from the wheel.
 Disengage the upper lever and release the outward pedal so that the wheel is free and
removed.

3.3 AIR-CONDITIONING AND REFRIGERATION

This is the second branch to which I was exposed during the period of my attachment. Mr
Aniefiok Inyang was in charge of this section. All the parts of an air-conditioner and a
refrigerator are given below with their functionality. There are:

(a) Compressor: Also called the prime mover. This is more or less the engine of any refrigerator
or air-conditioner. It is the most important part of the refrigeration set up. Within it is contained a
piston which drives the compressor and the compressor coolant, together with the compressor oil
which facilitate the smooth running of the compressor and the entire system. It is responsible for
the pumping and circulation of refrigerant fluid through the entire system.
 (a) An AC compressor (b) Compressor used in deep freezers

Figure 4.0 Compressor

(b) Condenser: "In systems involving heat transfer, a condenser is a heat exchanger used to
condense a gaseous substance into a liquid state through cooling. In so doing, the latent heat is
released by the substance and transferred to the surrounding environment. Condensers are used
for efficient heat rejection in many industrial systems. Condensers can be made according to
numerous designs, and come in many sizes ranging from rather small (hand-held) to very large
(industrial-scale units used in plant processes). A refrigerator uses a condenser to get rid of heat
extracted from the interior of the unit to the outside air"[15].

Figure 3.10 Condenser

A condenser (or AC condenser) is the outdoor portion of an air conditioner or heat pump that
either releases or collects heat. A condenser's function is to allow high pressure and temperature
refrigerant vapor to condense and eject heat [16].
(c) Evaporator: The evaporator works the opposite of the condenser, here refrigerant liquid is
converted to gas, absorbing heat from the air in the compartment. When the liquid refrigerant
reaches the evaporator its pressure has been reduced, dissipating its heat content and making it
much cooler than the fan air flowing around it. This is the part of the refrigeration system that is
doing the actual cooling. Because its function is to absorb heat into the refrigeration system
(from where you don't want it), the evaporator is placed in the area to be cooled. The refrigerant
vaporizes from the heat it absorbs heat in the evaporator"[17].

Figure 3.11 Evaporator

(d) Control Panel (Mother/Circuit board): This is similar to a brain box in an automobile. It
electronically controls the working operation of the refrigerator or air conditioner and as
expected contains all the minute electrical components necessary such as resistor, diode,
capacitor etc. One major form of diagnosis for a panel is the use of a special screwdriver called a
tester to touch a point where electric current can be transmitted on the board while the board is
connected to the wall socket. If the light in the screw driver comes on, then the circuit board is in
good working condition. If not it needs to be replaced.
 Figure 3.12 Control panel
(e) Thermostat: "This is the control center of the entire air conditioning process, reading the
indoor temperature and telling the air conditioner when to turn on and off. You change
temperature settings here based on your needs."[18]. The main role of an air conditioner
thermostat, is to regulate the temperature within the air conditioned space, to the set temperature.

Figure 3.13 AC thermostat

(f) Accumulator: An accumulator is to an air conditioner what a drier is to a refrigerator or cold
room (ice making) machine with other added functions. "An accumulator is a small, cylindrical
structure containing a system of pipes. An input pipe connects the accumulator to the evaporator
of an air conditioning unit. An output pipe connects the accumulator to the compressor of the air
conditioner. Evaporators exist as part of an air conditioner's low-pressure system, while
compressors comprise part of the high-pressure system. Accumulators converts refrigerant from
its low-pressure form to its high-pressure form [19].
 Figure 3.14 AC accumulator
The accumulator protects the compressor and also prevents compressor failure due to liquid
slugging. It retains moisture and contaminants from the system (during the accumulator's
lifetime) and ensures that only refrigerant is returning to the compressor [20].

(g) Dryer: As the name implies, it dries and filters moisture from air in the system to enhance
and make cooling efficient and effective. If there is still vapour or moisture in the system during
the cooling process, the cooling process will not be effective as it should be. "Refrigerated dryers
are the most common type of compressed air dryer. They remove water from the air stream by
cooling the air to approximately 3 °C (38 °F) and effectively condensing out the moisture in a
controlled environment.

Figure 3.15 Dryer

A filter- drier in a refrigeration or air conditioning system has two essential functions: one, to
adsorb system contaminants, such as water, which can create acids, and two, to provide physical
filtration. [21]

3.3.1 Relevant Tools and Equipment

The tools relevant to this branch of engineering are:

(a) Flaring tools set, (b) Wrench (adjustable spanner), (c) Screw driver, (d) Gauge Manifold,

(e) Vacuum pump, (f) Hack saw, (g) Swagging Tool, (h) Easy flow, (i) flux (j) Brazing torch
(Welding nozzle) with cooking and oxygen gas tank

(a) Gauge Manifold (b) Flaying/Swagging

tools set (c) Wrench spanner

(d) Vacuum Pump (e) Hack saw (f) Brazing Torch

Figure 3.16 AC and Refrigeration tools

3.4.2 THE THEORETICAL PROCESS BEHIND AIR-CONDITIONING AND

REFRIGERATION

The process of refrigeration and air-conditioning is broadly classified under the principle of heat
transfer. Naturally heat is transferred in the direction of lower temperature. However in
refrigeration, the revere is the case. Heat rather is pumped out from a region of lower
temperature to a region of higher temperature in order to cool it. "The transfer of heat from a
low-temperature medium to a high-temperature one requires special devices called refrigerators.
Refrigerators, like heat engines, are cyclic devices. The working fluid used in the refrigeration
cycle is called a refrigerant. The most frequently used refrigeration cycle is the vapor-
compression refrigeration cycle, which involves four main components: a compressor, a
condenser, an expansion valve, and an evaporator. The refrigerant enters the compressor as a
vapor and is compressed to the condenser pressure. It leaves the compressor at a relatively high
temperature and cools down and condenses as it flows through the coils of the condenser by
rejecting heat to the surrounding medium. It then enters a capillary tube where its pressure and
temperature drop drastically due to the throttling effect. The low-temperature refrigerant then
enters the evaporator, where it evaporates by absorbing heat from the refrigerated space. The
cycle is completed when the refrigerant leaves the evaporator and re-enters the compressor. [22].

3.2.1 SPLIT SYSTEM AC INSTALLATION PROCEDURES

1. Setting up the Indoor Unit

 Select an unobstructed location on your interior wall to mount the indoor unit. You'll need
to cut a hole through the wall to feed the pipes from the indoor unit to the outdoor unit, so
make sure the location you choose will allow you to do so. Choose a spot away from direct
sunlight and heat sources for the best results.

Fig. 3.10 Setting up the indoor unit

 Mount the unit 7 feet (2.1 m) off the floor and ensure there’s at least 6–12 inches (15–30
cm) of open space on every side of the unit to allow for proper airflow. Choose a location
with studs to ensure the wall is strong enough to hold the weight of the unit. Install the unit
at least 3.3 feet (1.0 m) away from antennas and power or connecting lines that are used for
television, radio, home security systems, intercoms, or telephones.
 Secure the mounting plate to the interior wall. Hold the mounting plate against the wall
where you want to install the indoor unit. Use a level to make sure it is both horizontally
and vertically level. Use a pencil to mark the locations of the screw holes, remove the
plate, then drill a hole into the wall where each screw will go. Position the plate so it
matches up with the holes, insert plastic anchors into the holes, and secure the plate to the
wall with tapping screws.

Fig. 3.11Securing the mounting plate

 Drill a 3 in (7.6 cm) hole through the wall so you can feed the pipes outside. Make a mark
in the center of the hole in the mounting plate. Use a keyhole saw or a drill with a hole-
cutting attachment to create a circular 3 in (7.6 cm) opening through the wall that slopes
slightly downward toward the ground to ensure adequate drainage. Make sure there are no
pipes or wires behind the wall before drilling or cutting the hole.

Fig. 3.12 Drilling holes

 Check the electrical connections on the indoor unit. Lift the A/C unit’s front panel and
remove the cover. Make sure the cable wires are connected to the screw terminals and that
the wiring matches the diagram that came with the unit.

Fig. 3.12 Connecting the electrical wires

 Run the pipes and cables through the hole in the wall, then connect them to the unit. Secure
the included copper pipes, power cable, and drain pipe together with electrical tape. Place
the drain pipe on the bottom to ensure a free flow of water. Run the pipes and cable
through the hole in the wall, then secure them to the designated spots on the indoor unit as
directed by the instruction manual.

Fig. 3.13 Drain pipe

 Secure the indoor unit to the mounting plate. To attach the air conditioner to the wall,
simply align the female connections on the back of the unit with the male connections on
the mounting plate and press firmly to secure the unit in place. Make sure the unit tilts
backward 2-3 degrees so that water can flow out of the drain pipe.
 Fig. 3.13 Indoor unit

2. Installing the Outdoor Condenser

 Position the outdoor unit away from any heavily trafficked, dusty, or hot areas. Find the
hole you drilled through the mounting plate for the interior unit and position the exterior
unit within 50 feet (15 m) so the piping and cable can easily be attached. Choose a
location with at least 12 inches (30 cm) of space surrounding its perimeter to ensure
proper functioning. If possible, select a shady location that’s sheltered from the wind in
addition to dust and traffic to keep your unit functioning at its best.

Fig. 3.14 Outdoor unit

 Lay a concrete pad on the ground. Don’t place the outdoor unit directly on the ground, as
it’s heavy and can shift around on dirt or rocks. It’s necessary to install the condenser on a
concrete pad, which you can find at home improvement stores. Position the pad where you
want to install the unit and use a level to make sure it’s flat and even.
 Fig. 3.15 Concrete pad

 Secure the outdoor unit on top of the concrete pad. Lay a rubber cushion on top of the pad
to minimize vibration, then set the outdoor condenser unit on top of the pad. Secure the
unit to the concrete with anchor bolts.

Fig. 3.16 Securing the outdoor unit

 Check the electrical wiring in the outdoor unit. Remove the cover on the condenser. Refer
to the unit’s wiring diagram in the instruction manual and make sure the wires are
connected as the diagram suggests. Make any adjustments as necessary. Fasten the cables
with a cable clamp and replace the cover.
 Fig. 3.17 Checking the electrical wiring

 Connect the piping and cable to the outdoor unit. Use flare nuts to secure the 2 copper
pipes from the indoor unit to the outdoor unit as per the instruction manual. Connect the
power cable that runs from the indoor unit to the outdoor unit as well. And finally, connect
the power supply to a designated outlet.

Fig. 3.17 Connecting the pipe

3. Completing the Project

 Bleed the air and humidity from the refrigerant circuit. Remove the caps from the 2-way
and 3-way valves and from the service port and connect a vacuum pump hose to the
service port. Turn the vacuum on until it reaches an absolute vacuum of 10mm Hg. Close
the low pressure knob and then turn off the vacuum. Test all of the valves and joints for
leaks, then disconnect the vacuum. Replace the service port and caps.

Fig. 3.17 Air and humidity bleeding

 Affix the piping to the wall with clamps. To ensure the pipes and cables don’t move around
or become disconnected, attach them to the exterior wall of your home using the clamps
that came with the kit. Follow the directions in the manual to ensure the clamps are spaced
adequately.

Fig. 3.18 Affixing the pipes with clamps

 Seal up the hole in the wall using expanding polyurethane foam. Spray expanding
polyurethane foam into the hole you drilled to feed the cable and piping through the wall.
Make sure the hole is completely sealed to prevent hot air or insects from getting through.
Let the foam dry as per the instructions on the label before turning on your air
conditioning.

Fig. 3.19 Sealing up the holes

 Turn on the unit and enjoy the cool air! All that’s left to do is to start the A/C, which you
can do from the indoor unit. It should only take a minute or 2 for cool air to start blowing
into your home.
 CHAPTER 4

OVERVIEW OF THE EXPERIENCE GAINED

4.1 EXPERIENCE GAINED WITH RESPECT TO UNIVERSITY TRAINING

From my training I have come to better appreciate the theoretical concepts that I have been
taught in the classroom. Concepts like Internal Combustion Engines (ICE), lubrication system,
suspension system, carnot cycle etc, now makes more sense to me. I have certainly gained more
practical experience and can understand certain vague concepts more clearly. From my
experience during the entire duration of the attachment, it is easier to understand engineering
when it is backed up with concrete practical experience. Although a good number of the
workshop floor staffs are not so good at using the English language to express themselves, they
can be good sources of knowledge that is far more relevant to Nigeria's industrialization agenda.
Though our school staff can better express themselves in vocal language, the artisans are an
indispensable bunch to the overall engineering process

4.2 Experience gained with respect to workshop studies

With respect to what I have been exposed to in the school's workshop courses, this is a
consolidation on that with regards to safety, accuracy, materials and tools handling among
others. The student's work experience program carried out in year two and three has been
helpful. It has enabled me to easily adapt to the industrial environment I was exposed to with
regards to safety, punctuality etc
 CHAPTER 5

CONCLUSION AND RECOMMENDATION

5.1 PERSONAL PROBLEMS ENCOUNTERED

(a) Personal problems: During the duration of the attachment, I did not encounter any major or
longstanding issues related to the training itself. Welding though was a challenge for me and I
could not eventually progress in that area.

(b) Workshop: Problems encountered at the workshop were minimal as they environment was
conducive and serene for work and comfort. Some minor inconsequential misunderstanding with
technicians had little or no bearing on the training acquired.

(c) University: There was no interval given by the school for holidays considering the stressful
nature of the training. This can result to fatigue and affect the results of the students as we head
into a new semester.

5.2 RECOMMENDATION/SUGGESTION

I respectfully suggest that the ITF officials should be urged to come around the student's places
of attachment for documentation and evaluation as we students had to incur more expenses by
having to pay our way down to the ITF office in the absence of due payment by our respective
institutions.

I also suggest that in future that student’s school fee for the mandatory attachment period be
reduced as students have little or nothing to do around the school premises during that semester.

Finally, I also strongly suggest that the stipend to be paid to the students by the federal
government through the industrial training fund be promptly processed and disbursed to the
students as this will greatly ease the expenses on transportation.

5.3 CONCLUSION/SUMMARY

The industrial attachment (I.e. student's industrial work experience scheme) has been a
worthwhile experience at training the Nigerian student to practical knowledge. I have gained
substantial knowledge and skill on tool handling, automobile servicing and automobiles in
general and also in the area of air-conditioning and refrigeration as well as welding and
fabrication. Summarily I can troubleshoot certain problems in an automobile, in air conditioning
and refrigeration and can give suggestions on how certain fabrication problems can be solved.
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