weekly breakdown

D i e s e l a n d M o t o r E n g i n e e r i n g P L C 6 5 , J e t a w a n a R o a d , C o l o m b o 1 4 , S r i L a n k a + 9 4 1 1 2 4 4 9 7 9 7

S.Y. Anushka Santhika Thenuwara

4226445

IBL – Weekly Breakdown

HEW050: Industrial Based Learning – Weekly Breakdown

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Week 1 (01/09/2011 – 11/09/2011) Department: Machining Description: This is my first allocation in the company. I was an assistant machinist in this department and I was in overalls and safety shoes. My working hours are from 8.00am – 5.00pm with the lunch break of 30 minutes at 12.30 pm. This department is fully capable of complete engine overhauling. The services provided are as follows, crankshaft re-grinding, cylinder block boring and honing, line boring of main bearing parent bores, connecting rod reconditioning, cylinder head overhauling and de-carbonising with tappet adjust, pressure checking cylinder blocks and heads, cylinder block and head facing, valve seat cutting and facing. A typical job takes about three to four days. Mitsubishi engines, Toyota engines and Tata engines are the most frequent engines that we overhaul. The workshop is moderate in size (2500 sq ft) and about 30 mechanics handle the work. Firstly, all engine blocks and engine heads undergo a pressure test to ensure that there are no internal cracks in the engine. Then only the engine undergoes overhauling. It is compulsory because, there is no point in overhauling an engine with internal leaks. From all the above services, my first appointment is with the connecting rod reconditioning station. Firstly, I learned the procedure involved in processing a connecting rod to get to the desired outcome. Based on the senior machinist’s description, I managed to derive a flowchart on processing connecting rods. The other main learning is the extensive use of meteorological equipment to obtain precise measurements. I observed the machine operation in connecting rod recalibration. Week 2 (12/09/2011 – 18/09/2011) Department: Machining Description: Due to the cramped up time of two weeks, I shifted my attention to other machines in this week. The main general learning at the first machining station is that, I learned to what to look for when I moved onto other machinists. Next up was the engine head modifying station. Likewise earlier, I managed to derive a flowchart for the workflow involved with overhauling an engine heads, followed by line boring and cylinder boring and honing. I observed the machining process and the preliminary setting up of machines. By referring to workshop manuals, I also obtained knowledge in some of the machining errors and remedies involved with cylinder boring and honing. Apart from this, I also got involved in lapping of valve seats. Cleaned many types of cylinder heads and obtained the knowledge on manual tappet adjust. Above all, the most significant learning is the intense usage of metrological tools. There were two types of prominent measurements, one was the bore measurements (connecting rods, parent bores, cylinder bores etc.) and the other was the centring of bores prior to machining. All these measurements were at the hundredth of a millimetre scale. Above all, getting to know the people at work was a nice experience; they were very helpful and polite. I felt blessed, as there was no ragging or any type of harassment upon new trainees. Week 3 (19/09/2011 – 25/09/2011) Department: Unit Repair Description: During this week, I was transferred into a department called ‘Unit repair’. This was under the same workshop manager Mr. Malika Senasekara as the machining department. Unlike the engine exposure in the machining department, this department was more into vehicle parts repair. The


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specialty is that, this department only cater to the vehicle part repair of Mercedes Benz, Jeep and Chrysler. There was a serious change in tools from measuring and machining equipment to a full-scale mechanic’s tools box. Almost all the tools were new to me and I had a hard time at the beginning. The workshop size is small (300 sq ft) and the team consists five heads. An engine block replacement of a Jeep Grand Cherokee took place when I came in. It is worth noting that the customer was into get the latest Jeep in his old one, but coincidently at the showroom, the old one’s engine failed due to a valve seat loosening. Apart from ordering the replacement Jeep engine, work was low; however, I was involved engine heads and suspension bush replacements. I decarbonised engine heads and cleaned gearboxes; did tappet adjusting and valve seat lapping. The work was similar during the whole week and one job stretched a couple of days too. Another unique experience is with AKUBIS Direct, which is a web based cast of exclusive videos on technical repairs of Mercedes Benz cars. During the free time, I watched these videos to gain knowledge and looked into the workshop workflow. Week 4 (26/09/2011 – 02/10/2011) Department: Unit Repair Description: The highlight of this week is the disassembling of a Mercedes Benz 7G-Tronic automatic gearbox. The fault was unsmooth gear shifting and a replacement of the gaskets took place. We noticed an impossible corrosion in the gearbox control module during this repairing. This is impossible as the module is a controlled flow of gearbox oil and it is dipped in oil. However, the corrosion has occurred as the vehicle had been caught in a flood. I highly regard this experience as this showed me the complex arrangement of the planetary gears and clutches of an automated transmission gearbox. Apart from this, I dismantled a small four forward one reverse ‘Tata’ manual gearbox and cleaned it. By this, I understood how the gear is linked to the gearbox and how a sliding mesh manual gearbox works. More work on engine heads and suspension bush replacements followed. I also watched many videos on AKUBIS Direct in the free time, replacing a C class front bumper, installing the AMG styling kit of an E Class, innovations of the radar-based Active Blind Spot Assist warning system are some of the videos that I watched. Week 5 (03/10/2011 – 09/10/2011) Department: Bosch service centre Description: Got into a new department this week, called the ‘Bosch service centre’. This is a workshop dedicated towards Japanese vehicles and Bosch products. It comprises of a vehicle repair section, a diesel pump room and an alternator repair station. Unlike the unit repair department, the focus is more on the middle class market and part repair over part replacement is very common. In this week, I was in the vehicle repair section, which includes about 35 technicians (including trainees). There are six head technicians and there about five to six trainees for each head technician. My main work during this week was mechanical repairs and repairs related to diesel injectors. Cleaning injector and setting to the right injector pressure by shim adjustment is what caught my mind. There was a special incident with an Isuzu Trooper on an injector misfiring noise. We cleaned the injectors, pressure tested, replaced and even did a pump recalibration; but the noise did not go. However, after the pump recalibration, the noise did die out but it was temporary. It took some time to recognize that the injection pattern of the injectors were different from that of the manufacturer recommendation, this caused the misfiring noise. A correct replacement resolved the issue.


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Week 6 (10/10/2011 – 16/10/2011) Department: Bosch service centre Description: I was in the injector pump room during this week where I got introduction to the diesel pump, which fascinated me greatly. The pump room has only a few numbers of trainees and the work is complex; however, there are about 10 experienced technicians handling the repairs. Bosch diesel pump repairs, service and spare parts are the main scope of this department. The main task is to calibrate the pump through the pump calibration machine. To do this, we crosscheck the volume flows of diesel through each pressure outlet with that of the manufacturer specification. My work was mainly to disassemble and clean the pump components. By now, I noticed a change in my skills; I faced difficulty in recognizing mechanical fastener sizes quickly in my first days. It pulled me into an embarrassing situation but my skill only developed and now, it is much more of a simple task. The pressure testing of injectors is also a task that I can handle. Finally, though disassembling looks as an extremely simple task, vital attention is necessary, as that knowledge is required in reassembling. This constant memory storing and recalling is another aspect that came up. Week 7 (17/10/2011 – 23/10/2011) Department: Passenger Vehicle services Mercedes Benz Description: This is an exclusive workshop on Mercedes Benz after sales service. This is the largest workshop I was in and there was a mechanical repairs section, electrical repairs section, wheel alignment bays, a body shop, a paint shop and vehicle servicing areas. In addition, the previously mentioned Unit Repair Department provides with vital support. The uniqueness is that all the cars undergo a vehicle inventory check before entering the workshop. Out of all the subsections, I was allocated in the mechanical repairs section during my stay at the Benz car yard. There is a team-based approach similar to what was there at Bosch centre. The teams are lead by a technician and are in groups of three. My role is to provide support with the mechanical repairs. The mechanical repair section mainly deals with running repairs of a car and focuses on part replacement. In this first week, I got going with the teams, made a lot of friend. The first thing I noticed is that this workshop is heavily equipped as it is the company’s main business. The tools are more up to date, the working environment is much cleaner, the working ethics and standards are higher and the environmental consciousness is higher, which adds on class and quality. All the vehicles under repair have steering wheel covers, seat covers and fender covers to keep the vehicle clean. The first repair was a replacement of brake pads of a C Class, followed by another front shock absorber replacement of another C class. Generally, a team performs about four to five jobs on a given day. Week 8 (24/10/2011 – 30/10/2011) Department: Passenger Vehicle services Mercedes Benz Description: The highlight of this week is with the Star diagnosis system. This is the computer-based interface between the operator and the engine control unit and it is unique to Mercedes Benz. We perform a star diagnosis in most of the cases to pinpoint the fault in the vehicle. This system is very powerful as it not only detects issues, but also can fine-tune all the electronics in the car. The first learning was the technical naming of the vehicles; example, W212 – The latest E Class; W221 – The latest S Class (as of 2012). Apart from learning the vehicle naming, I also performed vehicle fault diagnosing


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through this star diagnosis system. However, I was under constant overlook to ensure that I do not change any vehicle settings. Among this new exposure, I also performed daily jobs such as Hydraulic front shock absorber replacements of W204 (C Class), Pneumatic suspension replacements of W218 (CLS) and W220 (S Class), Bearing play adjustment, mechanical services (Which includes: Engine, ATF, Differential, power steering oil replacement, Shock absorber play check, Suspension check and Break pad check) etc. Among the cars, my attention was highly on the repair of an AMG SL 55. Though it is six to seven years old, it is a high end sports car and I was very enthusiastic over its presence. The repair was to service the braking system the team performed a brake bleeding to change the braking fluid. Usually we just manually replace brake oil with the help of a brake oil compressor; however, the SL 55 required the start diagnosis system to perform a correct brake fluid changeover due to the electronics governing the braking system. Week 9 (31/10/2011 – 06/11/2011) Department: Passenger Vehicle services Mercedes Benz Description: The third week at this department came with another excitement. It is the arrival of the SLS AMG (vehicle with ‘gull wing’ doors) for its first after sales service. All the staff was excited to have a closer glimpse of the car and I was no exception. Unfortunately, that job did not cross into our team; however, the task was to check the vehicles fluid levels and to check the functionality of the vehicle components. Apart from this, another major vehicle landed on our team, it was a dignitary’s bulletproof S 600. Due to the heavy-duty components, the work required double the effort. Firstly, we changed two bulletproof tyres of the front wheels, which was hard and performed a computer assisted wheel alignment, which was extremely hard; it is an unforgettable experience. Another type of work was PDI, which stands for Pre-Delivery Inspections. It is to check fluid levels, check the electronics and a visual inspection of the vehicle body and under body. I performed PDIs on several C and E class models, which are quick moving in the market. Another interesting task was the replacement of a radiator module of a W203. The engine overheats faster due to a coolant leakage in the radiator, to fix this; the radiator was to be replaced. Unlike in normal vehicles, the radiator comes with the power steering oil-cooling module. The job was interesting as it was a deviation from the usual suspension, break and engine checks and managed to get an understanding on the water cooling system of the vehicle. Week 10 (07/11/2011 – 13/11/2011) Department: Passenger Vehicle services Mercedes Benz Description: The fourth and the final week arrived; I felt a bit sad as the Benz experience is at an end. As a summery, the following is a list of all the tasks I came across whilst my stay at this department:

The technical naming of the vehicles (for example the latest C class as of 2011 has the tag as W204)

Computer assisted wheel alignment system

Observe and attempt configuring through the Start Diagnosis system

Hydraulic front shock absorber replacement of W204 (C Class)

Pneumatic suspension replacement of W218 (CLS) and W220 (S Class)

Air mass flow sensor replacement of W221 (S class)

Radiator module replacement of a W203 (C Class)

Water-cooled alternator replacement of a W203 (C Class)

Cleaned exhaust system of a W163 (ML)


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Bearing play adjustment

Wheel speed sensor replacement

Break bleeding (vehicles such as SL55 that has a SB control module, requires the assistance of the star diagnosis system)

Normal tyre removal, replacement and wheel balancing

Bulletproof tyre replacement of W221 (S 600)

Pre Delivery Inspection (Which includes: Engine oil level check, Automatic transmission fluid level test, Power steering oil level check, Coolant level check, Fill wiper washer with water, Differential oil level check, replace wiper blades, Set tyre pressure, Torque wheel nuts, electronics check)

Performing mechanical services (Which includes: Engine, ATF, Differential, power steering oil replacement, Shock absorber play check, Suspension check and Break pad check)

Even though I allocated in the mechanical repairs section, I did go into other sections and had a glance at their operations such as painting, color mixing, polishing (nano polish), and repair on accident cars with chassis pulling bench, electrical repairs. Week 11 (14/11/2011 – 20/11/2011) Department: Industrial Engineering Division Description: From this week onwards, I found myself in the Engineering divisions. This is where I was fully exposed to projects, field visits and corporate culture. The first department is the Industrial Engineering Division and it specializes in supplying, installation and after sales services of industrial pumps and cranes. The principals are KSB AG (Germany) on industrial pumps and DEMAG Cranes & Components GmbH Germany (Germany) on industrial cranes. In this first week, I went through the basics of an engineering team; how it works, and got an understanding on the scope of this department. Our scope was to cater to the building sector (high-rise buildings, hotels hospitals), the government sector (water supply projects) and the private sector (manufacturing plants). Knowing the scope made me understand the market segments in our business. Another exposure is on a vital tool in engineering project execution is tenders. Though I have seen tender callings on the newspaper, this is the first time I am exposed to one. During this week, I encountered the huge procedure behind that simple advert. There are many aspects in tenders, the deadlines, the technical specifications, the legal aspect, the competition, the money etc are overwhelming. Our services come in at the post design stage in ordering equipment; tenders to supply and install are very common at this stage. Anyhow, we receive pump specifications most of the time and our main task is to select, import and install pumps on customers’ demand. It includes critical coordination and a high degree of documentation. Apart from that, the department also carries out developing the pump motor control panels and pump house piping. Another plus point is, all the department members were mechanical engineers; it gave me a sense of belonging as I’m studying mechanical engineering myself. Week 12 (21/11/2011 – 27/11/2011) Department: Industrial Engineering Division Description: This week I faced another challenge, it is the theory. As engineers, In order to recommend a pump, one should know functionality and the technical details of a pump. I referred to many product manuals and catalogues to get this knowledge. Main parameters of a pump that concern a particular application are the flow rate, the discharge head, speed of rotation and the Net Positive Suction


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Head (NPSH). We provide the best pump even though power consumption, efficiency and price are secondary requirements. We use pumps in the industry segments of water, wastewater, energy, building services and mining. Applications vary from gas pumps, slurry pumps, fire protection pumps, A/C chillers pumps, water treatment pumps, rainwater pumps, seawater pumps, chemical pumps, hot water pumps etc. Another speciality of this department is the direct link with the Dimo Building Technologies division. Fire protection systems are a segment that is in their scope and fire protection pumps are necessary. Therefore, the pumps division is frequently in touch with the building technologies department on supplying water pumps. Week 13 (28/11/2011 – 04/12/2011) Department: Industrial Engineering Division Description: I also got the chance to get to the field with the service engineer and the technicians this week. First, I went to the ‘Omega Line’ garment factory (at Pannala) to attend to a pump leak. The leak was due to a failed mechanical seal in one of the six MEGA pumps (used to circulate the chilled water of the Air Conditioning system). Though we replaced the seal, the leak did not stop. We removed the impeller by the back-pull-out mechanism and noted rubble inside the pump housing. These solids scrape the seal and cause the leak. We discovered that an improper welding on the piping has introduced the rubble into the piping. We notified the client of this development and further serviced the pump. Second, I went on a service check on a government water supply scheme at a rural area (Puththalama) with the service and project engineers. The area lacks rain and surface water sources due to the scorching heat under the sun. Submersible borehole pumps elevate the underground water to an overhead reservoir, after which the water distribution follows. I also got the chance to visit a water treatment plant while on the way there. Third, went to inspect a sewage pump installation at the army quarters in Colombo (Narahenpita). It was an addition of two KRTU pumps (swage pumps) to an existing septic tank. This was a time critical modification as it took place with occupied apartments. Week 14 (05/12/2011 – 11/12/2011) Department: Industrial Engineering Division Description: This week I occupied the pump workshop. The main task undertaken at this is to repair and service pumps. It should be mentioned that most o the pump related mechanical troubleshooting is undertaken at the sight. Another important task is the development of the pump control panel. It is heavily involved with electronic sensors, relays, timers and circuit development. This is the control interface between humans and the pump. This fascinated me to learn more about electronics and inspired me to undertake the available electronic minors in the degree programme. Following is a list of components in a typical pump control panel: Terminal box, Contactors, Overload relays, Starters, Timers, Phase failure relays, Miniature circuit breakers, Residual current devices, MCB type isolators, Moulded case circuit breakers, Motor protective circuit breakers, Switches, Surge arrestors, Capacitors, Frequency inverters/Variable Speed Drivers (VSD), Control relays and Panel meters. These components are of extreme importance as it protects the pump from overloading, sudden surges of current, smooth starting of the pump etc. This makes the system energy efficient; provide protection for the expensive system, ease of automation etc.


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Week 15 (12/12/2011 – 18/12/2011) Department: Storage & Material Handling Equipment Description: This week I was assigned in the Storage and Material Handling Equipments department. They specialize in supplying racking systems solutions for warehouses and material handling equipment. The associated brands are Schaefer Systems International Pte Ltd. (Malaysia) on racking systems and Komatsu Ltd. (Japan) and STILL GmbH (Germany) on material handling equipment. Firstly, I was involved with the racking systems and the experience was project like, because it included designing and lying of the racking system. The main parameters are available storage volume, stored material type (pallets or not), isle spacing, storage capacity and rack system type. There are many types as selective racking systems, double deep racking system, mobile pallet racking systems etc. Type selection is based on accessibility, stock rotation, picking rate, protection, and floor condition and storage height. Work always starts with a visit to the site with a Bosch DLE 70 (laser distance measuring tool) to measure the space availability. Based on the measurement we do AutoCAD drawings depicting the plan view and front/side elevations of the rack system. We send this to Schaefer to get their modifications and approval; Schaefer also uses this to quantify part requirements. It takes about eight weeks for manufacturing of parts and importing. In this week, I got the chance to visit several warehouses. One is the visit to the warehouse of ‘Scan’ (brand in food and beverage industry) with the business unit manager. The requirement was to extend the existing pallet based selective racking system. The existing system was of a different brand but we took those measurements to match with Schaefer standards. Our manager extended the services to install safety barriers to protect the old system, which pleased the client. I also went to ‘Noyon Lanka’ garment factory to get measurements for a selective racking system and a Schaefer satellite system. The garment factory is a joint venture between France and ‘MAS Holdings’ (apparel giant). Some other visits were to a DIMO Tata parts store extension and a local rice mill. These were also to get measurements and I accompanied the department CAD specialist. Finally, a visit to the ‘Singer’ warehouse with the business unit manager to promote dock levellers is worth mentioning. Week 16 (19/12/2011 – 25/12/2011) Department: Storage & Material Handling Equipment Description: In this week, I got to work with the material handling equipments section. The experience deviated a bit from projects and focused more on sales of engineering equipment with the scope of warehouses storage solutions. In selling a material-handling vehicle, there are many more variables than that of the industrial pumps department. The main reason is that the client requirement is much more basic, examples, client needs to lift a weight of 1.5tons to 6meters etc. Due to this simplicity, an element of exploring is present in recommending warehouse vehicles, such as, folk options, mast height to match door heights, in/out door usage etc. a proper recommendation is only made after considering all these parameters. There are many types of material handling equipments, such as forklifts, reach trucks, stackers, order pickers etc. Following parameters are vital on recommending a vehicle: the type of client business, the type of cargo (pallet or not), lifting weight, lifting height, obstacles (containers and doors), floor conditions, working area (indoor/outdoor). These inputs define the mast stages, mast height, carriage nature (side shifter options), counter weight, tyre type, propulsion (electric – indoor/ diesel – outdoor) and many other parameters of the vehicle.


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Week 17 (26/12/2011 – 01/01/2012) Department: Siemens Power Engineering Description: This department specialises in building solutions and automation systems. The focus is on fire detection, protection and suppression; public addressing; access control; CCTV systems and building management systems. The main principals are Siemens AG (Germany), Siemens Ltd. (India) on fire detectors and control panels and Axis on CCTV camera. This is where I was fully exposed to tender based and contact based work. The work demand very specific technical and financial requirements. A project-based approach is there to fulfil these obligations. Knowledge about the product is vital to meet and satisfy demands on the tender (certain production standards, technical specifications, applicability etc). Numerous deadlines are there to obtain work and the initial challenge is to develop a ‘Bill of Quantities’ (BoQ) abiding the tender specifications. There are two main parameters in a BoQ, they are direct costs (imported products) and indirect costs (system commissioning, labour but mainly wiring). To determine these costs, we study schematic diagrams. The most common type of tender is supply and installation where it specifies all the products and the number of products. Design and build type is there too where we have to decide on the products and the amount. I got directly involved in a major design and build building project, which was the ‘Keells city’ project. It IS A massive urban city construction of six buildings that includes hotels, shopping malls, car parks, offices etc. I laid CCTV cameras on the schematic diagrams and calculated wiring lengths. Through this project, I got an immense exposure into networking, cable design in buildings and CCTV camera technicalities.

Week 18 (02/01/2012 – 08/01/2012) Department: Siemens Power Engineering Description: The work continued on the ‘Keels city’ project, which required me to refer to many Cad drawing layouts to come up with the first design to quantify CCTV cameras, public addressing speakers, access control modules, wiring lengths, data switches etc. Due to the high workload, this project seems to go into the upcoming weeks as well. Developing a bill of quantities will be a very tedious task. While doing this project, I looked into some administrative aspects of a department. I had a chat with the department manager to know his role. His input is that, he is responsible for the budgeting and profit generation of the business and must justify their performance in front of the director board. Budget for financial year, Income/payment /monthly targets, Follow ISO rules and regulations, Human Resource management, Trouble solving, Keeping records, Monthly meeting with employees, Takes care of all the bills (IT fees, medical fees, employee payment etc) are some of the key areas that a manager looks into within the business unit. Apart from this, the manager was kind enough to share his knowledge on the industry and what is expected out of a degree. In his view, an engineering degree is a measure of a person’s ability to tackle problems, ability to read and understand then think to develop solutions and professionally presents the solution; regardless of the knowledge attained while following the degree. I see a true side to it as I had to learn everything from scratch during this training at DIMO.


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Week 19 (09/01/2012 – 15/01/2012) Department: Siemens Power Engineering Description: I noticed the levels of CAD drawings involved in a project, they are,

Design drawings: Drawings done to get an idea about what devices go where and to get a general idea about wiring lengths and other requirements and highly involved in the tender stage.

Shop drawings: Drawings with much specific details, such as, dimensions, positions, wiring paths, switches etc which is vital in installation and which are highly involved in the construction stage.

As built drawings: Drawings that depicts the real distribution of components after the construction and highly involved in the post construction stage. This is useful for future references and for maintenance purposes.

While doing the ‘Keels city project’, I was assigned to a different type of a tender (supply and install). I laid and calculated fire resistant wiring for a fire detection system of a bank (Commercial bank, Wellawaththa). In this, I got the exposure into fire resistant cables, fire detector system, BoQ preparation and pricing. Apart from this, I learnt about the import procedure during this week. It starts with the client placing an order, then DIMO starts to deal with the foreign supplier by sending a purchase order. Based on this the supplier sends a performance invoice, to which DIMO (or client) open a payment method (Telegraphic Transfer or Letter of Credit). Then the supplier sends the shipping schedule, which includes the commercial invoice, packing list and the airway bill (AWB) (or Bill of Laden (BL)). Products arrive to Sri Lanka based on the mode of shipment (Ex – work, Free on Board or Cost Insurance Freight. Finally, after DIMO clears shipment, the goods are sent to DIMO stores (If client directly pays the suppler, the goods go to the site and we collect commission from the suppler) which eventually converge to the client. Week 20 (16/01/2012 – 22/01/2012) Department: Siemens Power Engineering Description: This week I got to know more about what a BMS system is. BMS stands for Building Management System. In all buildings, there are three main systems, they are heating ventilation and air conditioning. Heating, Ventilation and Air Conditioning (HVAC) consumes a lot of energy in buildings. Nearly 40% of world energy goes to power buildings and it is responsible for 21% of green house gases; therefore, to manage these systems a BMS is there. A BMS is a computer based control system installed in a building that control and monitor the buildings’ mechanical and electrical equipment (such as, ventilation, lighting, power systems, fire systems and security systems). The system is integrated via internet protocols and open standards (such as, DeviceNet, SOAP, XML, BACNet, LonWorks and Modbus). The communication language in Siemens products is BACNet (Building Automation and Control Networks). The Keels city BMS had several unctions, which is, Event oriented communication, Peer to peer communication, Alarm and message processing, distribution to local operator unit and building automation and control system, Scheduler programs with weekdays, Calendar function, Local trend recording in device buffer. Following were the levels if the BMS;

Management level – The graphical interactive interface for the operator to the automation station and the integrated plants and plant parts

Automation level – Individual room control automation stations


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Field level – This level comprises all measuring sensors, actuators1, transmitters and energy devices used to control, regulate, monitor and optimize plants o Sensors: Temperature sensors, Humidity sensors, Temperature with Humidity sensor, Air

quality sensor Pressure sensor o Controllers: Damper actuators, Valves and valve actuators, Immersion thermostats,

Variable speed drives, Water/mechanical heat meters, Transmitters Week 21 (23/01/2012 – 29/01/2012) Department: Siemens Power Engineering Description: This week got to know more about the administrative aspect of DIMO in projects. The two sectors DIMO serves are the government sector and the private sector. We behave in two ways in these sectors. DIMO is a main contractor in the tenders from the government sector as the government calls for tender bids after dissolving their projects in to small elements. Therefore, in these, the contractor becomes the main contractor for that particular task. However, in the private sector it is different. Due to the scope of DIMO, we handle most projects at the as subcontractor level or at the local agent for the brands. Once a project is done, there are the following documents DIMO hands over to the client:

Handing over certificate

Test certificate

Fire equipment installation certificate (from Fire Department) o Automatic sprinkler system o Automatic gas suppression system o Wet riser system o Hose reel system o Foam inlet o Two-way fireman communication system o Automatic and manual addressable fire alarm system o EXIT signs o Fire extinguishers

Warranty certificate

Operating instructions and operating manuals

Test records

Megger test report (to measure current leakage through cable wires of about 600V rating)

Pressure test report

Technical literature Week 22 (30/01/2012 – 05/02/2012) Department: Siemens Power Engineering Description: This week was all about the fire detection, protection and suppression system. The Fire system is the most important system of the building as it protects and saves lives. There are four main objectives of having a Fire Detection/Protection system. It is to reduce the risk of starting fires, to limit and circumscribe the risk of spreading of fire and smoke, to guarantee the swift and safe evacuation of occupants, to facilitate the intervention of emergency operations. In supplying the fire detection

1 Actuator – Is a device that converts electrical/hydraulic/pneumatic signals into motion


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protection and suppressing system, is not only the sprinkler system and the fire pumps. It also includes the Automatic Fire Detection and Evacuation Alarms (AFDS), Automatic gas detection (CO detection), Safety emergency lighting and safety signals, Portable fire extinguishers, First aid kits and Hose systems etc. The brain of the Fire system is the fire alarm system and the control panel. This is where all the decisions are made based on the sensory inputs. This system has several components such as, Smoke detectors, Neutral smoke detectors, Optical smoke detectors, Thermovelocimetric detectors, Manual alarm buttons, Optical acoustic devices for the evacuation alarm, Fire detection station, Interfaces for communicating with other technical installations, Associated electronic networks, Door stops. Conventional fire alarm systems could only notify that there is a fire in the building; however, new systems can notify conditions and whereabouts of the fire due to the analogue addressable field devices. (Analogue: capable of measuring fire condition; Addressable: capable of giving an address to the device so we can locate it). Apart from this, there is a fire-fighter intercom system, where fire fighters can communicate from each level with the ground floor base. On fire detection cabling, a 1.5mm 2 fire resistant cable connects all manual-call-points (break glass buttons), smoke and heat detectors. This loop is the signal line circuit (SLC). A 2.5mm2 fire resistant cables supply power to the fire alarms and sounders, as they require higher current in sounding the alarm; however, the alarms and sounders are also connected to the SLC. Fire resistant cable

Fire resistant test – the rated voltage is supplied through the wire, which is subjected to a flame of 7500C for 3 hours. Within 12 hours, the circuit is re-energized for 3 hours and the circuit integrity should remain.

Flame retardant test – the wire is burnt vertically on three levels as A, B and C (A: 7l/min for 40 min; B: 3.5l/min for 40 min; C: 1.5l/min for 20 min) and the burnt length should be less than 2.5 meters

Halogen content and corrosive test – Halogen content should be less than 0.5% after burning. On corrosiveness, the burnt gas pH value should be greater than 4.3 and the conductivity should be less than 10μs/mm. (pH 0 = acidic; μs/mm 0 = resistive)

Smoke density test – wire is burnt in a control volume of 27m3, after which the light transmittance should not drop below 60%

Week 23 (06/02/2012 – 12/02/2012) Department: Siemens Power Engineering Description: This week I got to know more about the CCTV camera system and crime security of building. The components of these systems are as follows. Indoor alarm system, Closed Circuit TV (CCTV) surveillance system, Access control, Centralized danger management system (CDMS). A CCTV system was a unique experience; it had a digital aspect, which fascinated me. Following is a breakdown of a basic CCTV system and its components.

Auto iris vari-focal lenses – top lenses that enables variable focusing and light input for optimal video quality

Multiplexor – an electronic devise that switches between input signals

CCTV recording methods Digital Video Recording (DVR) Network Video Recording (NVR)

Codec – Device or programme that performs encoding and decoding on a digital video stream

Video encoding MPEG4/H.264 – motion recording MJPEG – takes high quality pictures at time intervals

Smooth motion is at 30fps but for viewing and recording 15 fps is enough


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Aspect ratio 16:9 (HDTV) is advantageous as less wasted pixels at top and bottom

Frequently used Axis camera products Indoor Dome Cameras Indoor Standard Cameras Indoor PTZ Cameras (Pan, Tilt, Zoom) Outdoor Dome Cameras Outdoor Standard Cameras Outdoor PTZ Cameras (Pan, Tilt, Zoom)

I also got the chance to visit the new customs head office of Colombo. Our scope of the project is the building management system, CCTV system, fire detection and access control. It was a unique experience to see Direct Digital Control panels, fire detection panels (the loop cards and panel programming), CCTV monitoring station, server rooms etc. It felt wholesome to see the design come to life. As a note, when it comes to fire suppression systems, there is a requirement of fire pumps. Our own industrial solutions division provide us with these pumps; therefore, inter department sales highly take place. The industrial pumps division only provide products and solutions for building pumping, where as this building technologies division goes further to link up all the systems of a building to a panel and automate. Week 24 (13/02/2012 – 19/02/2012) Department: Siemens Power Engineering Description: As this was the final week, I had to meet up with the previous managers and the human resources department to obtain my letters and recommendations; however, I got to know more about the standards involved with building technologies which are as follows, BMS

EN15232 – European standard for Energy performance of buildings – impact of building automation, controls and building management

eu.bac – European building automation and control association Fire fighting regulations

BS9990 – Code of practice for non-automatic fire fighting systems in buildings

BS9999:2008 – Code of practice for fire safety in the design, management and use of buildings

BS EN 12845 – 2004 + A2:2009 – Code for area classification according to hazards

BS EN 54 – specify requirements for all component parts of a fire alarm system Wiring

BS 6004 – code of practice in PVC insulated wiring

BS 6346 – code of practice in PVC insulated wiring

BS 4662 – code of practice in joint boxes


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Wire spacing There should be a physical separation between power cables and telecommunication cables to avoid electromagnetic noise issues in data networks. The following spacing is for a category 6A network:

Cable No

divider Aluminium

divider Metallic divider

Power Not shielded 200mm 100mm 50mm

Telecommunication Not shielded

Power Not shielded 50mm 20mm 5mm

Telecommunication Shielded

Power Shielded 30mm 10mm 2mm

Telecommunication Not shielded

Power Shielded 0mm 0mm 0mm

Telecommunication Shielded

I was able to end this training on a high with going back and obtaining positive feedback on my work from my managers and with a little treat to all the departments. They are looking forward for my return which gave me great confidence on myself. This training has showed me insights on the mechanical engineering industry and persuaded me to expand my knowledge in electronics. It was a natural decision for me to select robotics subjects for my minor. All in all it was great experience.

weekly breakdown

Documents

d i e s e

cylinder boring

cylinder bores

engine heads

cylinder head overhauling

cylinder block boring

cylinder blocks

engine blocks