sampson tubonimi report
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CHAPTER ONE
1.1 BACKGROUND INFORMATION
The student industrial work experience scheme (SIWES) was established by the
industrial training fund (IT) in 1973 to solve the problem of lack of adequate
practical skills preparatory for employment in industries by Nigerian graduates
of tertiary institution.
The student industrial work experience scheme students to improve and
industrial based skills. It is an imperative need for every Nigerian students to
achieve a smooth transition from classroom practice to the word competitive
work. It also affords students of tertiary institutions the opportunity to
familiarize and expose themselves of handling machinery and equipment which
are usually not available in the equational institutions.
Students industrial work experience scheme (SIWES) has become a necessary
pre-condition, for a student to participate before they are awarded a diploma and
degree certificates in specific disciplines in institutions of higher learning in
Nigeria, in accordance with education policy of the government.
An industrial training experience within the exploration and production
organization such as JOVETEC has exposed me to leading technology tool in
the area of production, HSSE and provided me with practical skills required forworking in the industry. The work experience have guided me to use practical
applications and broaden my knowledge in most of the theoretical concepts, I
learnt in the classroom over the years of my tertiary education at the Rivers
State University of Science and technology Nkpolu Port Harcourt Rivers State.
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1.2 ABOUT JOVETEC CONST./ENGR. COMPANY
The JOVETEC CONST./ENGR. COMPANY is one of the most promising
Engineering Company in Nigeria. It exploits in various areas of engineering
disciplines especially in production engineering. It also has its link expanded
towards oil and gas sectors.
Jovetec Const./Engr. Companys operations are servicing of Heavy Duty
Engines such as G3306 Engines, overhauling of engines of various types and
dimensions.
The company employs more than 1,000 staff. Ninety five percent of whom are
Nigerians. In addition, more than 20 people are employed by contractors
working for JOVETEC and projects that creates opportunities for tens of
thousands more jobs with contractors in supporting industries.
JOVETEC is committed to sustainable development and therefore supports
developments and progress within communities in areas of operations. Theoverall goal of our social investments programmes is to leverage the resources
and empower local communities to take lead in their development process.
Above all, JOVETEC Const./Engr. Company believes in the future of the
country and the company is committed to its development.
1.2.1 MISSION OF JOVETEC
The mission of JOVETEC is to be the operator of first choice in Nigeria through
its commitments to strong economic performance and to every aspect of
sustainable development.
1.2.2 VISION OF JOVETEC
To become the industry leader, employers of first choice and a company that
delivers as promised.
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1.2.3 HISTORICAL BACKGROUND OF JOVETEC
JOVETEC CONST./ENGR. COMPANY started business in Nigeria 1990. It
was initiated by a man called ENGR. JOHNSON AGWU and with a total of 50
staff in 1990. Due to their effective and efficient method of
production/servicing, there has been an increase in their organizational
structure/increase in organizational goals.
1.2.4 GEOGRAPHICAL LOCATION OF JOVETEC
JOVETEC CONST./ENGR. COMPANY is located at 238 Aba-Port Harcourt
Express Road Aba, Abia State.
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CHAPTER TWO
2.1 INTRODUCTION TO MECHANICAL WORKSHOP AND
EQUIPMENTS
Mechanical workshop is a mechanical maintenance department in JOVETEC
CONST./ENGR. COMPANY which is based on trouble shooting and
overhauling of caterpillar engines and crude oil pumps of different models.
Mechanical maintenance workshop is further divided into different sections
such as engine bay, accessories section, cylinder head section, Clutch section,
radiator section, pump section etc.
2.2 ENGINE BAY
An engine is a power unit that operates either in four strokes or two strokes
cycles that drive rotating equipments such as pumps and alternators etc.
In this bay we worked on different model of caterpillar engines such as G3304,G3306, D3304, D3306, G342, G3408, G3412 D3408, D3412, G3508, G3512,
D3508, D3512 and D3516 etc.
Before ever we repair or overhaul an engine, we first of all trouble shoot to
know the fault of that engine. If it is a fault that affects the internal part of the
engine, that means, the engine will undergo complete overhaul. Meaning strip
down of the engine and change the parts that are faulty.
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G342 CATERPILLAR ENGINE SET
2.2.1 COMPONENTS PARTS OF AN ENGINE AND THEIR
FUNCTION
2.2.1.1 PISTONS
This is a component part of an engine that helps to increase the temperature and
pressure of the air fuel mixture in the combustion chamber for combustion to
take place easily.
2.2.1.2 CONNECTING ROD
This is the rod that connects the piston to the crankshaft of an engine.
2.2.1.3 GUDGEON PIN
This is a pin that holds the connecting ROD firmly to the piston.
2.2.1.4 LINNERS OR CYLINDERS
It is just like a slip or cylinder in which the piston is fit in.
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2.2.1.5 CRANKSHAFT
This is the power house of an engine. It converts the reciprocating motion of the
connecting rod to a rotary motion.
2.2.1.6 BEARING
It helps in reducing friction in rotating parts of the engine.
2.2.1.7 OIL PUMP
It pumps the oil from the oil sump to the lubricating parts of an engine.
2.2.1.8 OIL FILTER
This is a component that fitter the oil before the oil pump pumps the oil to the
lubricating parts.
2.2.1.9 FUEL FILTER
It filters the fuel before getting into the engine.
2.2.1.10 OIL COOLER
This is part of engine that cools the heated oil before getting back to sump. Its
construction is of tube and shell. The water that cools the oil passes through the
tube while the heated oil passes through the shell.
2.2.1.11 WATER PUMPIt pumps water from the radiator and send it to the water jacket in the engine
block.
2.2.1.12 CAMSHAFT
This is a part that is linked to the crankshaft that pushes cam followers, then the
followers pushes the push rod and pushes the rocker arm assembly for the
opening and closing of values.
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2.2.1.13 OIL BAFFLE
It is a seal that seal the crankshaft of the engine so that there will be no oil
leakage from that end.
2.2.1.14 FAN BLADE
It blows out the heat through the core of the radiator.
2.2.1.15 FAN DRIVE
This part is linked to the crankshaft with the aid of belt which drives the fan
blade.
2.2.1.16 RADIATOR
It cools down the hot water that comes out from the engine to a required
temperature before sending it back to the engine with the aid of a water pump.
2.2.1.17 GOVERNOR
It regulates the speed of an engine, when it is loaded, it will increase or reduce
the speed by opening and closing of the butterfly valve in the carburetor.
2.2.1.18 THARMOSTAT
This is the part of an engine that regulates the temperature of an engine. When
the water in the engine is hot the thermostat will open itself for the hot water to
get into the radiator.
2.2.1.19 MAGNETO
This is the part of the engine that generates current in the engine, but the current
it produces is very small.
2.2.1.20 IGNITION COIL
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This part increases the low current that is being produced by the magneto to a
high current that can ignite the engine.
2.2.1.21 SPARK PLUG
This produce spark that can ignite the air fuel mixture in the combustion
chamber.
2.2.1.22 INDUCTION PUMP
It pumps dieseline into the engine.
2.2.1.23 NUZZLE
It is a component that gives fine spray of the fuel into the combustion chamber.
2.2.1.24 FUEL LINE
It is the line in which fuel from the induction pump is being transferred to the
NUZZLE.
2.2.1.25 RADIATOR PRESSURE CAP
This is the cover of the top tank of the radiator.
2.2.1.26 TURBOR-CHARGER
This is the part that increases the efficiency of the engine and it is always
located at the exhaust pipe.
2.2.1.27 AIR CLEANER
It is the component that filters the aim that goes into the engine.
2.2.1.28 AFTER COOLER
After cooler cools the air that get into the engine.
2.2.1.29 AUXILIARY WATER PUMP
This pumps water to the supercharger of the engine.
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2.2.1.30 GAS REGULATOR
It regulates the amount of gas that goes into the engine.
2.2.1.31 CARBURATOR
It mixes the gas that comes from the gas regulator and the air that comes from
air cleaner to the required ratio and sends it to the engine according to the firing
order of the engine.
2.2.1.32 STARTER MOTOR
Its function is to crank the engine. There are two types, the electrical type
known as kick starter and the mechanical type known as air starter.
The electrical type makes use of motor battery while the mechanical type makes
use of air.
2.2.1.33 PULLEY AND DAMPER
It is the component part of an engine that absorb the vibration that is being
caused by the crankshaft in the engine and it also transfer the rotating motion ofthe crankshaft to the far drive with the aid of the fan belt.
2.2.1.34 BREEDER
Its function is to expel the vaporized gas that comes out from down the sump
apart from the combustion chamber.
2.2.1.35 SERVICE METER
This is to indicate weather the engine has riched the period of service.
2.2.1.36 SUPPER CHARGER
This performs the same work as the turbo charger but can be differentiated with
their power drives. The turbo charger gets its power drive from the exhaust
stream while the supper charger gets its powers drive from the crankshaft and it
is connected to the crankshaft with the aid of belt.
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2.2.1.37 FERULES
It protects the water that comes out from the cylinder head via water galleries
not to get into the engine.
2.2.1.38 ACTUATOR
This regulates the speed of the engine, it collects signal from the electronic
governor.
2.2.2 STRID DOWN OF AN ENGINE
This simply means decoupling or disassembling of all the component parts of an
engine. As I stated earlier, we worked on different model of caterpillar engine
but let me use G342 as a case study.
Start by draining the oil in the sump and the water in the radiator. After then
commence disassembly and keep nuts, bolts, washers, studs etc belonging to the
equipment together. Ensure proper separation of parts.
Decouple accessories like fan drive, starter motor, water pump,
carburetor, radiator etc and send to accessories section with job order.
Carry out thorough inspection of the accessories and ensure that they are
in good condition, otherwise overhaul using genuine parts and carry out
the appropriate test where necessary.
Remove valve covers/valve mechanism, carefully unbolt and remove
cylinder heads and sand to the cylinder head section with job order for
overhaul and pressure testing.
Turn engine over on inspection stand and remove sump, connecting rods,
pistons crankshafts, journal bearing, timing gears etc.
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Extract engine liners
Scrape off mating surfaces of the engine block and other parts to remove
remains of old gaskets.
Wash parts in suitable solvent to dissolve oil dirts and rusty scales,
steam clean all stripped parts.
Polish all the mating surfaces with emery cloth.
Carry out dimensional test on major components (e.g crankshaft; liners,
pistons etc) and confirm any deviations from standard values based on
OEM specification in particular crankshaft straightness check and wear
should be eared out.
After detailed inspection and all necessary measurement, prepare a strip
down report showing the list of reasonable and non reasonable parts.
Generate scrap report and parts to the yard.
Generate list of a new spares required to augment the reusable parts and
seek for approval from the appropriate authority.
2.2.3 BUILDING OF AN ENGINE (G342)
This means putting all the components parts of an engine back to its normal
fitting position. This can be done by introducing the following steps.
Use compressed air to blow all the galleries in the engine block.
Installation Of Liners: Put the liners seal on the liners and then press
the liners in the liners chamber with the liner installer.
Installation of Crankshaft: Ensure that the female part of the journal
bearing is fit on the engine block and the male part on the cap of the
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journal, then place the crankshaft on crankshaft end of the engine block
and the with aid of plastiguage determine the clearance of the crankshaft
and the bearing and ensure that it falls within the range prescribed. Then
guard the bolt and torque according to manufacturer specification.
Ensure that the bearings are placed key to key. Journal torque wretch
value for G342 is 3501bF. Plastiguage measurement for G342 journal
0.006.
Installation of Pistons: Ensure that the pistons wrings are fixed on the
pistons accordingly as oil ring, scraper ring and compression ring. The
rings should also be positioned in different angle. Also mount the
connecting rod on the piston and carefully fix the piston on the engine
block with the aid of piston installer. Also ensure that clearance is
checked, then guard the bolts and tighten according to manufacturer
specification. The torque wrentch value is 190IbF while that of the
plastic gauge measurement for connecting rod is 0.003.
Mounting of Camshaft: Ensure that timing mark of the crankshaft align
with the timing mark of the camshaft. The timing mark of some engines
are always symbolized as C while others are always symbolized as
V.
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Mounting of Magneto Drive: Be ensured that the timing mark of the
magneto drive align with the timing mark of the crankshaft.
Mounting of Timing Cover: Ensure that the timing cover gasket is well
placed before tightening to avoid leakages.
Mounting of Oil Sump: First of all mount the oil pump on the sump
then place the oil sump gasket on the engine block and ensure that it
does not shift from its fitting position then lift the oil sump with the aid
of crane and belt to be placed on the engine block and guard the bolts
and tighten.
Mounting of Flywheel Housing: Lift the flywheel housing with the aid
of crane and belt place it on the end of the engine block, then guard the
bolt and tight it according to the manufacturer specification and the
torque wretch valve is 150IbF.
Mount the front engine leg and turn the engine with the aid of crane and
belt.
Mounting of Cylinder Head: Place ferrules and top cylinder head
gasket on the engine block then lift the cylinder head with the aid of
crane and belt, use compressed air to blow the cylinder head and place it
on the engine. Ensure that the cylinder head is well lapped before
guarding the bolt and tighten according to manufacturer specification.
The cylinder head have two sets of bolt, one is small while the other one
is big. The torque wrench value of the smaller both is 190Ibf while the
torque wrench value of the bigger bolt is 350Ibf.
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Mounting of Oil Throughwer: Ensure that it is heated to about 900c for an
expansion before putting it on the flywheel view of the crankshaft.
Mounting of oil baffle
Mounting of Flywheel: Ensure that the timing mark of the flywheel is
align with that of the crankshaft. Also ensure that it is torque according
to manufacturer specification and the torque wrench value is 2016f.
Mounting of oil cooler, oil filter base, breeder, exhaust manifold and
inlet manifold.
Mounting of Pulley and Damper: Lift the pulley and damper with aid
of crane and belt place it on the front end of the engine then guard the
bolts and torque according to manufacturer specification. The torque
wrench value is 600Ibf.
Mounting of accessories of a engine such as water manifold, air state,
water host, fan drive, fan belt, gas regulator, butterfly value and
carburetor.
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Mounting of Magneto: Ensure that the flywheel rotates to about 250
after TDC of 1 and 6 before mounting the magneto so that it will be on
accurate timing.
Connection of Magneto to the Ignition Coils: Ensure that the wires are
connected to the ignition coil according to the alphabet and the firing
order of the engine (1 5 3 6 2 4). The numerical order indicates the
cylinders.
A - Ignition coil 1
B - Ignition coil 5
C - Ignition coil 3
D - Ignition coil 6
E - Ignition coil 2
F - Ignition coil 4
Mounting of valve Mechanism: Ensure that the push rod are place on
their fitting position before mounting the value mechanism.
Valve Setting: The valves are set according to manufacturer
specification. In valve setting turn the engine first revolution set the
valves and turn it to second revolution set again. Revolution means turn
the crankshaft of engine to 3600.
First Revolution Inlet 1 Inlet 2 Inlet 4
Exhaust 2 Exhaust 3 Exhaust 5
Second Revolution Inlet 6 Inlet 5 Inlet 3
Exhaust 6 Exhaust 4 Exhaust 2
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Mounting of Governor, air cleaner housing, radiator, exhaust elbow,
spark plugs, mofil panel, and mounting magneto pig up on the flywheel
housing.
When building of engine is completed, fill radiator with water and allow
for about 24 hours under atmospheric pressure, chock for leakage. If
water level remain the same, than fill engine sump with appropriate oil.
Carry out primary test run, adjust all the necessary parts accordingly.
G342 Engine being connected to Emsco pump.
2.3 CLUTCH SECTION
Clutch is a take off device that engages and disengages the motion of an engine
to pump for the purpose of pumping crude oil via belt and pulley connection.
Basically there are three types of clutch which are automatic or hydraulic clutch
that is operated with flutch.
Manually operated two plate clutch
Manually operated three plate clutch
2.3.1 COMPONENTS PARTS OF CLUTCH
Hub Assembly: It is made of hub, fiber plate, center friertional plate,
top plates, adjustment nut, lings, stopper spring.
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Shaft Assembly: It is made up the shaft itself, cone bearing, cups, cir
click, carrier, carrier lock nut, stopper bolt.
Sleave Assembly: It comprises the sleave, twin disc or coller, clutchfingers, host, cutter pin.
Leaver Assembly: It is made up of the clutch handle, the side shaft and
the yoke.
Clutch housing
2.3.2 STRIP DOWN OF TWO CLUTCH PLATE
The strip down procedure is as follows:
Remove all attach parts from the output end of the PTO shaft. Remove
the key from the shaft. Drain oil from sump of PTO. Remove dip stick
from housing. Removing support plate if used.
Remove the hex-head cap screws that came the PTO housing to the
flywheel housing. Remove the power take off from the engine.
Remove the hex-head cap screws that secure the drilling ring to the
engine flywheel. Remove the driving ring.
Set the power take off on a work bench supported by wood blocks with
the input and facing up.
Straighten the portions of lock plate which were bent against flats of the
heads of three hex-head cap screws, and remove the cap screws lock
plate and retainer washer from the end of the drive shaft.
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Use conventional gear puller and remove the spider and key from the
PTO shaft. Remove the rubber blocks from the spider only if
replacement of the parts is necessary.
Remove the six hex-head cap screws which secure the bearing support
carrier to the PTO housing, and remove the bearing carrier from the
housing using 3/8-16 pusher cap screws in the holes provided 180 0 apart
in the carrier. Remove seal ring from the housing.
Remove the internal snap ring which retains the roller bearing outer race
assembly in the bearing carrier. Remove the bearing and oil seal from
carrier. Tap seal forward and bearing rearward to remove.
Use a conventional bearing puller and remove the bearing inner race
from PTO shaft, pulling forward off of the input end of the shaft.
Remove the six hex-head cap screws which secure the bearing retainer
and shims to the PTO housing. Remove the retainer and shims from the
housing.
Attach a hoist with an eyebolt to the input and of the PTO shaft and lift
the shaft from the housing. You may have to tap the housing to unseat
forward bearing cup.
Remove the bearing cones and cup from the shaft, using a press or
conventional bearing puller.
Tap the oil seal from the housing.
Remove the two bearing cup access plays and with a long narrow shark
punch, tap out the rear bearing cup.
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Remove the four drive screws and remove the specification plate only it
replacement of the parts is necessary.
2.3.3 BUILDING OF TWO CLUTCH PLATE
Bearing inner races and/or cones, shift mounted, may be heated to not over
3000F in an oven or oil bath to facilitate assembly.
Install the specification plates securing it to the housing with four drive
screws if the plate was removed previously.
Install the pipe plug into the PTO housing and tighten securely.
Install the oil drain, oil plug and tighten seemly to 35-47Ibft torque.
Install the tapered roller bearing cup use a piece of steel tubing slightly
smaller than in O.D than the O.D of the bearing cup and about fifteen
inches long and squarely tap the bearing cup into its bore from front
toward rear with the cup back face (wide section) bottoming at the rear
of the bore. Install the two plugs in the holes at the rear of the housing
and tighten the plugs securely 7--1016s.ft torque.
Install the oil seal in its bore at the rear of the PTO housing press or tap
the seal securely into the bore until the steel casement is flush with the
rear surface adjacent to the bore. The dust lip section of the seal should
be at the rear prelubricate the seal with engine oil.
Press the two bearing cokes onto the PTO shaft so their back faces butt
against the collar machined on the shaft for the purpose.
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Press the inner bearing race onto the PTO shaft from the front securely
press the bearing race to but against the shoulder provided on the PTO
shaft, pre-lubricate the bearing race.
Set the PTO housing on a work bench supported with wooden blocks, so
the input end faces upward. Install the PTO shaft with attached parts into
the housing. Be careful, when entering the PTO shaft in the rear oil seal,
so damage of the seal is prevented.
Install the front bearing cup in its bore and press or tap it against the
bearing cone and squarely press the cup into position.
To select a shim park, of usually two shims to establish bearing free
play, proceed as follows.
a. Install the bearing retainer and secure it to the PTO housing with six hex-
head cap screws. Tighten the cap screws to a point where the bearing free
play is eliminated. Rotates the shaft several times and seat and align the
rollers. Use a set of filler gauges and measure the gap (shim) distance
between the bearing retainer and the PTO housing. Add 0.006-inch to this
measurement for bearing free play and select two shims which will
provide this thickness. Remove the six cap screws and bearing retainer
from the PTO housing.
b. Install the selected shim pack over the shaft and onto the bearing retainer
mounting surface on the PTO housing.
c. Install the bearing retainer and secure it to the PTO housing on top of the
shim pack with six hex-head cap screws. Tighten the cap screws to 38-
42Ibs-ft torque.
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d. Attach a dial indicator to the PTO housing. So the indicator plunger or
stem rests on the end of the PTO shaft, (Input end). Raise the PTO shaft
with a hoist to move the forward bearing cup against the bearing retainer.
You may have to tap the PTO housing downward.
e. Zero the dial indicator with the hoist released pick up the shaft with the
hoist. Rotate the shaft several times to seat and align the rollers. Note the
dial indicator reading from zero. Lower the shaft indicator should be zero.
The noted reading should be 0.006-0.010inch for proper bearing
adjustment.
Press the outer roller bearing race squarely into its bore of the bearing
carrier. The bearing race assembly is installed from the rear toward the
bottom in the bore. Press on the outer race of the bearing only. Install the
internal snap ring in its groove adjacent to the bearing to secure the
bearing in the carrier.
Press the oil seal into the carrier from the front the dust lip must be
forward and the steel seal casement must be flush with the front surface
around the bore.
Install the rubber oil seal on the pilot of the bearing carrier pre-lubricate
the oil seals position the bearing carrier with attach parts into the PTO
housing and secure it to the housing with six hex-head cap screws.Tighten the cap screw to 38-421bs.ft torque.
Install the spider key into the PTO shaft and install the spider onto the
shaft. Secure the spider to the shaft with a retainer washer, a lock plate,
three hex-head cap screw. Tighten the cap screw to 177-195Ibs.ft torque
upset the look plate tabs against the flats of the screw.
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Install new rubber blocks and required.
Install the driving ring on the engine flywheel.
Install the breather pipe into the PTO housing if removed. Install the
breathe and oil level gauges onto the breather pipe.
Swing the PTO assembly into position on the engine flywheel housing,
carefully, meshing the drive spider rubber blocks with the internal teeth
of the driving ring. Then secure the PTO housing to the flywheel
housing.
Install the support plate
Fill the unit with oil to full mark
Install key in PTO shaft, and attach all parts previously removed from
output shaft.
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CHAPTER THREE
3.1 MAINTENANCE OF INNER MECHANISM
This is a mechanism inside a positive displacement meter (PD meter) that is
involved in flow measurement. Is the qualification of bulk fluid movements it
accumulate a fixed times the volume is filled to measure flow. Flow can be
measured by measuring the velocity of fluid over a known area.
3.1.1 PRINCIPLES OF OPERATION
The A.O Smith meter is of the rotary positive displacement type. The accurately
machined housing contains a rotor which revolves on ball bearings and carriers
evenly spaced blades. As liquid flow through the meter, the rotor and blades
revolve about a fixed cam, causing the blades to move outward. The successive
movement of the blades forms a measuring chamber of precise volume between
two of the blades, the rotor, the housing the bottom and top covers. A continues
series of these closed chambers is produced for each rotor revolution. Neither
blades nor rotor contact the stationary walls of the measuring chamber.
One of the outstanding features of this meter principle, the flow is literally
undisturbed while it is being metered. Energy is not wasted by arresting liquid
velocity; consequently high accuracy and efficiency are common place with the
mater.
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FLOW STATION SHOWING PD METER
3.1.2 DISASSEMBLY OF INNER MECHANISM
The inner mechanism removal and disassembly procedures are as follows:
Take out the bolts that fasten the body to the housing.
Using the lifting hugs, remove the inner mechanism from the housing.
Take out all the cover screws, place cover screws into the tapped holes
using the screws as jack, remove the cover.
During disassembly of the inner mechanism, clearance may be checked
to determine the condition of the various parts. To be done accurately, a
spider should be used. The fixtures maintain inner housing
concentrically when the cover is removed.
Take out the machine screws and plate located on the underside housing;
remove the rotor from the housing. Lift out carefully to prevent
damaging the blades.
To disassembly the rotor, place the assembly upside down on a suitable
surface, loosen the socket head cap screw and lift off locating arm.
Remove the screws and clamps that secure the rollers to the rotor.
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Lift out the rollers and pins check for wear and smoothness of operation.
To separate the cover and rotor, pry up at the openings provided.
Lift off the cover
Remove the lower rotor bearing if it is still in place.
Lift shaft assembly, and take out the upper blade.
Turn the rotor over and remove the rotor gear plate.
Take out the screws that hold the plate to the rotor and lift off. Remove
the upper rotor bearing, spacer, and thrust bearing, if necessary, drivewith punch made of soft materials.
To disassembly shaft and cam, place shaft in press or vice to compress
spring so that pin cam be removed from the color.
The can may be removed from the shaft by pressing it off. A woodruff
key is used to prevent the cam from turning on the shaft.
The adjusting screw extension pin is removed from the shaft by taking
out the adjusting screw nut and washer.
Remove cotter pin and press out blade roller pin with a drill rod.
3. 1. 3ASSEMBLY OF INNER MECHANISM
Reassembly is essentially the reverse of the disassembly procedure.
Be sure to observe the reassembly precautions noted during teardown of the
unit.
1. Should it become necessary to install a new rotor assembly into a meter,
check rotor to blade clearances, refer to clearance check section.
If clearances are too small, block should be removed and the necessary
clearances provided by filing metal from the back of the block.
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If clearances are too great, the block should be shimmed to provide
proper clearances.
Dress all rotor all edges lightly with file to remove any burs.
2. New blades installed into a rotor must be fitted to the motor case.
Position any two adjacent blades to their furthest extension position.
Raise the assembly to a position over the inner limit.
Line up rotor so that extended blades are just inside of the indentations
in the case at either end of the measuring chamber.
Slowing, lower rotor assembly into position in the inner housing.
By means of adjusting screws, lower rotor until it bottoms, it spider is
used there should be some clearance between the rotor and base.
Care must be taken when installing the inner unit cover to assure that the
rotor gear and the lower jackshaft gear are properly meshed.
Total end clearances is divided, top and bottoms by setting the rotor
adjusting screw.
Loosen the adjusting screw lock nut and while turning the rotor, slowly
raise the rotor assembly until it just begins to bind against the top cover.
With the rotor in this position, check the bottom rotor clearances at both
the inlet and outlet ports compare with clearance guide.
By means of adjusting screw lower rotor until 1/3 of this clearance is at
the tip and 2/3 is at the bottom.
Add 0.002 0.004 to the top clearances to allow for the frightening of
the lock nut.
Tighter adjusting shaft lock nut and check top and bottom rotor
clearances to see that they are 1/3 off the top and 2/3 off the bottom.
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If these clearance do not check, loosen lock nut and repeat the complete
adjusting procedure.
After this adjustment has been satisfactorily completed, and lock nut
tightened, record this measurement as as assembled clearances.
5. Determine rotor to block and blade slot clearances.
6. Assemble inner unit into outer housing.
Clean the machined surfaces of the outlet port of the inner unit and outer
housing with alcohol or solvent.
Coat both surfaces with loctite master gasket or other sealing medium.
Lower inner unit into outer housing. Apply Vaseline or petroleum jelly
to the o-rings on the cap screws and installing washers, draw inner unit
up to seal outlet port.
7. Complete Reassembly
Coat p-ring with Vaseline or petroleum jelly and install o-ring in groovein top of outer housing.
Install cover. Be sure to line up locating pin in cover with hole in
housing flange.
Install all remaining parts and accessories.
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CHAPTER FOUR
4.1 CONCLUSION AND RECOMMENDATION
As stated earlier the contemporary relevance of the SIWES program can not be
over emphasized, and its benefits are much more numerous.
Every student who truly and fully participated in the SIWES industrial
attachment can testify to this facts.
4.1.1 PROBLEMS ENCOUNTERED (SIWES)
Although I have a wonderful time during the program, whose memory will
remain indelible in my sense of reminiscence. Nevertheless, I was also
confronted by some short comings related to safety and other industrial
problems. Actually at my work resumption day I was made to understand safety
rules.
1. Industrial Problems (Safety Equipments)
Incomplete issuance of personal protective equipments. At the
commencement of the training program, I was not given a complete PPE;
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such as Helmet, hand gloves and safety booth; this actually affected my
performance effectiveness at the very beginning of the training.
2. Supervisors Attitude
The attitude of some supervisors working with me was not so encouraging,
especially in sections like flow station and Gas plant etc. as they do not allow
the tools to be carried out directly or personally by me and some assisted me in
answering most of the difficult questions I could not answer whereas others are
not ready to give
any assistance on the work done.
3. Health Problem
This is an important aspect of the human life. In JOVETEC site and
surroundings are heavily polluted by some chemical waste products,
which are most considerably harmful to the human health.
4. NOISE POLLUTION
Noise pollution in JOVETEC is so intense that it should be looked into
properly. I observed that audiometric test is only done on the staff. The
contract staff and those on industrial attachment are not considered.
Supervisors and guidan
e from SIWES board and institutions should be sent as much as possible
to industries to properly direct, observe and instruct the participants were
necessary and student should be more enlightened before going for their
attachment.
I strongly appeal to the SIWES board/ ITF to ensured that every
institution attached importance to this program as well as attaching a
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credit unit, so that students can take it very serious as part of their course
work.
This phenomenon has become imminent considering that throughout mysix months stay in JOVETEC no supervisor, either from the SIWES
board or my department came see how we are coping.
4.1.2 WAYS OF IMPROVING THE PROGRAMME
Besides its relevance the SIWES program also has its short comings, most of
which can be over looked.
i. The SIWES can be made more efficient by increasing training
opportunities for the students, so that the goals and objectives could be
achieved satisfactorily.
ii. The necessarily working place should be provided for student by the
SIWES board, since most students are restricted in mobility due to
finance, to actually find a reputable place for themselves.
iii. Strengthening its requisite power capability to enable the companies or
firms to employ many students as possible, this can uplift the program
drastically.
iv. The industrial training fund (ITF) should increase the allowance paid at
the end of the program to enable student who are willing and ready to do
the program.
4. 1.3 ADVICE TO FUTURE PARTICIPANTS
Having fully participated in the SIWES Programme, i would humbly advice
future participants to firstly believe in God for a placement and make sure that
they take the programme with absolute diligence to enable them acquire
practical skills which are not easily obtainable in higher institutions of learning
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and they should also be punctual and show full commitment to their appropriate
duties, bearing in mind that this opportunity might never be given to them again
and finally they should be honest, transparent and hardworking. Above all they
should put up a positive mental attitude.
4.1.4 ADVICE TO THE SIWES MANAGERS
My advice to SIWES Managers is to try as much as possible to maintain the
continuity of the program. This is because of the fact that it helps student in
having the technical- know-how of their respective discipline.
Finally, I which to let them know that in spite of all their short comings, they
are still doing a good job by bridging the gap, which had been a barrier to our
educational structure.
4.1.5 CONCLUSION
Above all, it could be deduced that the program will go along way in generating
a pull of indigenous trained labor force, sufficient to meet the needs of the
economy. If the above views are taken into consideration. Thus, I see industrial
training as a very important part of the university training and its inclusion in
the curriculum is justified.
4.2 RECOMMENDATIONS
I wish to recommend on the following area which can necessitate the programto a higher level.
i. Students should be given instructors or supervisors from the university to
properly monitor the training.
ii. The University (RSUST) in Particular should attach a grade unit for the
industrial training; thus this will aid to taken the program seriously.
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iii. Industries should see that students within their jurisdiction are well
trained.
iv. Authorities concerned should ensure that allowance are paid shortly as
when due to be paid.
v. I also recommend the company I worked with, as place of attachment for
students.
REFERENCES
R.T. Pritchard, 1965, T3 Workshop Technology for Mechanical
Engineering and Technicians; S.I. Edition.
W.A.J. Chapman, 1946, Workshop Technology Part 2, Fourth Edition.
Port Harcourt Refining Company Limited Brochure. (2005 Edition).
PHRC C2
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