CHAPTER ONE

1.0 INTRODUCTION

The electrical/maintenance section is the power house of the

company. All other section depends of it, either directly or
indirectly. The major functions carried out in this section are
repairs of electrical equipments (grinding and cutting machines,
generator sets, welding machine compressors etc.) from site. It’s
also in charge of installing TV cables, telephone lines, repairing
and fixing of light fittings, construction of welding cables and
building of electrical panels. On rare occasions, the section is in
charge of supervision of house wiring of the company’s residential
area.

This report is into two chapters, the first chapters outlines the
importance and aim of SIWES, it gives an over view of the
company’s profile and a good representation of the organizational
structure of the management. The second chapter describes the
various industrial equipments, their mode of operation, how there
are troubleshot and repaired. Chapter three treats the
procedures for conduit wiring a with emphases on the working of
the electrical lighting arrestors and earth pit while the last is the
conclusive chapter which highlights the skills I acquired by virtue
of my training, the challenges I encountered and possible
recommendations.

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1.1 OBJECTIVE OF SIWES

The student industrial work experience scheme (SIWES) is a

federal government policy, which is aimed at assisting
students to obtain relevant practical experience and skills in
their course of study among other reasons; it is an effort
designed to bridge the gap between the theory and practical
aspect in various degree program. It also strengthens
employer’s involvement in educational process and also in
preparing students for employment.

1.2 COMPANY’S PROFILE

Alcon Nigeria Limited was launched into Nigeria

construction industry as LED construction Nigeria Limited on
the 10th of May 1982 and on the 30th march 1984 it was re-
named Alcon Nigeria Limit. It is located at plot 17 Trans- Amadi
industrial layouts, Portharcourt, Rivers state.

FIELDS OF ACTIVITIES

Alcon has track records of excellent project performance across

abroad industry spectrums either as a simple construction
contractor or as a main contractor responsible for turn key
projects in the following fields.

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• Oil and gas upstream and mid stream prospects

• Refining chemical and petrochemical

• Power generation and distribution

• Infrastructure

• Civil works.

I t is a full single source provider, a strategic partner ally for

• Project management

• Engineering procurement construction and installations

• Operations and maintenance

Alcon is committed to executing its projects safely without

compromising quality in a timely manner and within stated
budget.

SECTIONS

• Electrical / maintenance section

• Welding section

• Iron bending/ panel beating section

• Mechanical/automobile section
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 • Carpentry section

• Quality control department

• Account department

• Store department

1.3 MANAGEMENT ORGANOGRAM

Chairman

Director

Deputy General Manager

Quality Mngr. Maintenance Mngr. Utility Mngr. Store Mngr. Acc Mngr. Admin Mngr. Marketing Mngr.
Security Officer.

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Senior officer Maintenance Engr. Utility Engr. Senior officer Acc. Officer Admin Officer Marketing Officer
Asst. Officer

Officer Fore man Sub. Asst. Engr. Officer Cashier Asst. Admin Officer
Officer Security Guards

Lab. Asst. Helper Workers Helper

Lab boy Workers Workers

CHAPTER TWO

INDUSTRIAL ELECTRICAL EQUIPMENTS

They were some industrial electrical equipment I got

acquainted with. The machines are; welding machine,
generator set (big), grinding and cutting machine amongst
many others.

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2.0 WELDING MACHINE:

Welding machines are used to permanently connect metal

piece with heat generated from electrical energy. They are
available in variety of sizes and output voltage. Welding
machines takes electrical current from a high-voltage power
source and coverts it into viable energy to fuse two materials
together.

Some welding machine use a transformer to convert the high

voltage current from the wall outlet into a lower voltage
current for outlet while other types or welding machines uses a
motor or combustion engine to convert electrical energy into
mechanical energy. An alternator or generator is then used to
convert this mechanical energy into a low current electrical
output.

2.1 MAINTENANCE OF A WELDING MACHINE

I. The first thing to check when a welding machine is not

working fine is if the wire is feeding properly. A worn drive
roller can affect the feed and causes it to slip. When
checking, look for debris and dirt on the liner. This can
also cause bird hesting. Sometimes troubling shooting

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 welding machine is as simple as cleaning it and allowing
the wire feed freely.

II. Look out for the tip near the wire exist inside the gun. A
worn out tip doesn’t allow the electricity to efficiently hit
and this creates a lot more work on the job. Burn back
can cause a bad wire.

III. Inspect the ground clamp, when the part of the clamp is
coated with oxide, electrons can’t ready transfer. A bad
ground clamp can cause a lot of resistances and change
the way current comes back to the machine.

IV. Examine the welding cable for worn spots.

2.2 GENERATOR:

A big generator set used mostly in the company is the SA-200

Lincoln generator. It comprises of two DC generators working in
tandem. The first generator is the exciter (the nose that sticks out
the front of the machine. The exciter is actually a 2kw DC
generator that provides a DC current that is adjusted to control
the welder output. The exciter also provides an auxiliary 115 volts
DC for accessories.

The second generator is the welding generator. This generator

produces a regulated constant current output that produces the
wonderful arc, that the welder’s love. The fig below shows a
typical Lincoln SA-200 generator set.

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Figure 1; Lincoln SA-200 generator set

2.2a EXCITER PARTS LOCATION AND DEFINITIONS.

The graphic below is a standard Lincoln SA-200 exciter with cap

removed.

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Figure 2; lincoln SA- 200 exciter.

Facing the machine from the front the parts are named as follows:

1. The right hand brush holder is the positive spring loaded

brush holder.

2. The left-handed brush holder is the negative spring loaded

brush holder.

3. Behind the right brush holder is the right exciter coil.

4. Behind the left brush holder is the left exciter coil.

5. The exciter armature is held onto the armature shaft by nut

secured by a lock washer.

6. The brush springs the hold the brush in place.

2.2b HOW IT WORKS

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The exciter coils and the poles pieces form electromagnets. When
DC current flows through the exciter coil, the magnetic fields
produced by the exciter coils are broken by the winding on the
exciter armature producing approximate 115 volts DC at full RPM.
The faster the engine turns the more voltage the exciter
produces.

The system is a series wound compound generator, with an

additional shunt coil across the exciter armature. The fine current
control (heat control) rheostat varies the exciter voltage that is
applied to the main stator shunt coils, the variable control the
output current (heat) of the arc.

2.3 TROUBLE SHOOTING THE EXCITER FIELD COILS

In fig c below, the wiring diagram, you will see that there are two
halves of the exciter circuits. The exciter generator produces 115
volts DC that is fed to the auxiliary power outlet and to the main
exciter shunt coils. This DC current is varied by the fine current
control rheostat (like a valve) then fed into the main exciter
shunts coils. This controls the strength of the magnetic field,
which controls the amount of welding current that is a variable .A
fault in either circuit or the machine will not weld if the failure is
in the exciter shunt circuit the generator can still produce power.
This can be verified by checking the auxiliary with a meter, light

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or a grinder if you can grind but not weld the exciter shunt coil is
faulty.

Figure 3; the two halves of an exciter circuit.

2.3a HOW TO TROUBLE SHOOT THE MAIN EXCITER SHUNT

COILS

I. Reach under the exciter armature and locate the black and
blue leads, the wire should be connected with a butt splice
or bolted together. If they are spliced or connected with bolt
and nut, you must break this wire apart. It’s only then will
you be able to check the coils separately.

II. To check the exciter field coils, remove both exciter brush
from their holders and make sure they do not touch anything
while making measurement with the VOM on the lowest
resistance scale you can use, check resistance between the
right brush lead to each to the separated wire. If the wire is
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 good, one wire will show resistance, the other will not, this is
normal. The resistance should be approximately 130-170
ohms. If you get no resistance go to the next higher range
(make sure you do not touch the lead with your hand else
you could be reading the resistance of your body.)

III. The next thing to check is the resistance from each coil leads
to the outside terminal (it may have a red wire attached) of
the fine current control rheostat. One of the wires will show
continuity, between the lead and the rheostat. Both
measurements should be identical.

IV. If the measurement shows very high resistance or an “open

coil” infinite resistance, or a very low resistance(less than
100 ohms) the coil must be replaced.

V. If the coils check out ok, then the exciter armature will be
the next to be suspected.

2.3b TROUBLE SHOOTING THE EXCITER ARMATURE

The defects to look out for when trouble shooting an armature

includes:

1. Burnt or blacked commutator bar. Before further check,

clean the commutator with a commutator cleaning stone.
It is not normal for brushes to deposit enough carbon
powder to contaminate the commutator.
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Note: that a properly maintained commutator should be the
colour of a used burnished penny.

2. Inspect the windings for any burnt insulation, broken

wires, or damaged commutator bars. Armatures have two
problems. A winding that is shorted to the armature shaft
or broken (open) windings.

Note: if a bright green spark is seen when the unit is

running. That is a sign of a shorted (to ground) armature
winding.

3. Check for an armature shorted to ground. With the VOM

set to the highest resistance range to check for a short to
ground. This is done by placing one lead to a clean spot
on the armature shaft. With the other lead check each
commutator bar. If there is any resistance reading in any
of the cummutator then the armature needs to be
replaced.

4. Sometime a high bar may occur. A high bar simply means

that one of the commutator bars has come loose and is
sticking up. This makes the brush jump and results to
excessive sparking.

2.3c FLASHING THE FIELD

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The exciter field coils are held in place with solid iron “pole
piece”. The special pieces of iron do more than just hold the
exciter coils in place. They retain a small amount of residual
magnetism just a bit. They hold a small amount of residual
magnetism to provide “self-excitation” so the exciter will
start generating current from a dead start. The pole piece
can lose their magnetism as the unit sits idle for a long
period to time and there is no easy test to detect the loss.

When the exciter field coils, the brushes, and the exciter
armature check out, the only thing left to do is “flash the
field”. This is normally done with a 12 volts car battery, not
with standing in front of the machine in a trench coat. This is
how it is done:

1. Remove the exciter dust cover.

2. Connect jumper wires first to the battery then to the

exciter brush terminals.

3. Start the engine and makes sure it is running at its slow

speed.

4. Connect the positive (+) lead to the right brush lead

terminal.

5. Touch the negative (-) lead, to the left brush lead

terminal, you will generate a strong spark. Hold the
lead on the terminal for approximately two seconds

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 there will e strong spark the field poles will be
“flashed”.

Figure 4; shows parts of an exciter that is being flashed.

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The other machine that we repair and service at the work shop
includes; grinding and cutting machine. They are mostly used by
the welders, carpenters, panel beater and on rear occasion by
electricians. They are used for cutting metals, woods, smothering
rough surface, cutting almond cables etc.

2.4 HOW TO TROUBLE SHOOT A GRINDING AND CUTTING

MACHINE:

1. Check if the wire terminal at the plug of machine is

still tightly connected.

2. Check for continuity of the wire. This is done by

placing the leads of the VOM at the neutral and life
components of the wire. If a sound is heard from the
VOM, then the wire is in good condition.

3. Check if the carbon brush at both sides of the

machine located beside the armature is worn off. If
the brushes are worn off then they should be
changed or replaced.

4. If all the listed above have been checked and

rectified and still the machine doesn’t work at all, or
if it does, it brings out offensive odour, only then do
we go further to check the armature.
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On checking the armature, if it is covered with a black substance,
it is burnt and should be replaced or rewired.

CHAPTER THREE

3.0 CONDUIT WIRING

It is an electric piping system used for protection and routing of

electrical wiring. It may be made up of metal, plastic, fiber or fired
clay. The term conduit is commonly used to describe any system
that contains electrical conductor but it has a more restrictive
definition when used in wiring regulations.

Conduit wiring provides mechanical protection and electrical

safety to persons and property and provides convenient
accessible ducts for the conductor. A well designed conduit wiring
system has adequate capacity for future expansion. Varying
number, types and size can be pulled into a conduit which
simplifies the designs and constructions compared to multiple
runs of cable. Frequent wiring changes are made simple and safer
through the use of electrical conduit, as existing conductors can
be withdrawn, and new conductors installed with little or no
disruption along the path of the conduit. Some types of conduit
are improved for direct encasement in concrete. This commonly
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use in commercial building to allow electrical and communication
outlet to be installed in the middle of large open areas.

Metal and plastic conduit can be bent in the jobsite to allow neat
installation without excessive number of manufactured fittings.
This is particularly advantageous when following irregular or
curved building profile. Conduit wiring is more expensive than
other forms of electrical wiring. One major disadvantage of the
type of wiring is that it doesn’t dissipate heat as readily as those
installed in open wiring. Therefore it is advised that the current
capacity of each the conductor be reduced.

3.1 TYPES OF CONDUIT WIRING

i. RIGID METAL CONDUCT (RMC)

It is a thick treaded tubing usually made of coated steel, stainless

and aluminum. It is the thickest and heaviest of all other type of
conduit, and it can be use to run wire under drive way, service
feeder installation in extreme conditions.

Ii. GALVANIZING RIGID CONDUIT (GRC)

It is a galvanized tubing system. It common applications are in

commercial and industrial construction.

Iii. ELECTRICAL METALLIC TUBING (EMT)

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 It is sometimes called thin wall. It is commonly use instead of
GRC as it is less costly and much lighter, though it is damage
easy.

Iv. FLEXIBLE METALLIC CONDUIT (FMC)

It is made through the coiling of a self-interlocked strip of

aluminum or steel, forming a hallow through which wire can be
pulled. It is used mainly in dry areas where it would be impractical
to install any non-flexible conduit, yet where metallic strength
would be required. It doesn’t maintain any permanent bend.
Typical examples of where flexible conduit is applied are in water
heaters, attic vent etc.

V. ALUMINUM CONDUIT

It is similar to galvanized steel conduit. It is a rigid conduit

generally used in commercial and industrial application (in food
processing plants) where higher resistance to corrosion is needed.
Aluminum conduit cannot be directly embedded in concrete since
the metal will react with alkalis in the cement.

Vi. POLYVINLY CHLORIDE CONDUIT (PVC)

This is the most commonly used type of conduit because it is the

lightest and cheapest compared to other conduit materials. The
thin-PVC are only burial and exposed work.PVC resist moisture
and any corrosive substance. Since PVC has a higher thermal
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coefficient of expansion other types, it must be mounted so as to
allow for expansion and contraction for each run. Since it is not
conductive it is advised to always run green grounded (earthing)
wire in the conduit for proper grounding method at connection.
One major reason why PVC is preferred in conduit wiring is
because it is insulated. The figure below show a typical example
of a PVC in a junction box.

Figure 5; PVC conduit pipe.

3.2 FITTINGS FOR PVC CONDUIT WIRING.

* Box connectors; they join conduit to a junction boxes.

* Couplings; it connects two pieces of conduit bodies together.

* Condulets; they are used to provide access to wires placed

within the conduit it differ from a junction box which allows

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access for pulling wires and space for splicing. Condulets are in
various types, moisture rating and materials including galvanized
steel, aluminum and PVC. Some of the Condulets includes L-
shaped bodies, T-shaped bodies and –shaped bodies. The figure
below show some fittings for PVC wiring.

3.3 PIPING FOR PVC CONDUIT WIRING

MATERIALS NEEDED; PVC pipe, bending spring, male brush PVC

adhesive, Y-way junction box, U-junction box, 4-way wire
coupling, knockout boxes, nails sledge hammer, claw hammer,
wire strippers, hack saw, flat headed screw drivers, files, PPE.
Etc.

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 Piping is mostly done before plastering or decking, in cases
where the piping is done before plastering is done, then the
walls have to be broken and holes bored through which the
pipes will pass. When passing a pipe through a junction, the
PVC pipe needs to be bent using a bending spring, also if the
lent of the pie will not reach to its destination, couplings and
adhesive gums are used to extend the length. It is important
to note that during pipe, outlet boxes for switches, lightning
sockets are connected.

3.4 WIRING FOR CONDUIT

This is done after the piping activity. Here the major tools used
are; scaffold, fishing tape, wires of various sizes depending on
the circuit being wired. The table below shows the sizes of
cables used in some wiring units.

Table3.0

WIRING UNITS SIZES OF CABLES USED

Lightning points/ ceiling fans 2xI.5mm PVC single core cable

13Aswitch socket outlet 3x2.5mm PVC single core

cable

15A switch socket outlet 3x4mm PVC single core cable

Air conditioners, water 3x4mm PVC single core cable

heaters , cooker control units

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3.5 SURFACE MOUNTING RACE WAY/ TRUNKING

This type of decorative conduit is designed to provide an

aesthetically acceptable passage for wiring without holding it
inside or outside a wall. It is used were additional wiring is
required and were going through a wall will be difficult. A conduit
has an open face with removable cover secured to the surface
and the wires are placed inside it. It is often used for
telecommunication wiring such as network cables. Aside from the
fact that if the appearance may not be acceptable to the
observers, one of the major advantage is that it is easily be
accessible for future changes, thus enabling minimum effort
upgrading.

3.5 LIGHTENING ARRESTORS AND EARTH PIT

Lightning rods are designed to give lightening a safe part to

travel if it happens to hit a house. The lightening rod takes the
lightening along a part through the ground where it is dispersed
without harm to the building or its inhabitants. Installation is
carried out by connecting the upper layer to the down layer with
the connecting lead. The upper part consist of the following

• Gold plated centered needle

• Gold platted 45c bended flat needles

• Gold plated 90c bended needles

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 • Gold pated base ball

• Positive conductor

• Parabolic dish steel clamp.

The down layer include

• Negative conductors

• Copper plate

• Plate connectors

Connecting lead consists of 20mm/2m copper stripes. The copper

stripes are thoroughly insulated and concealed within a PVC pipe
from upper layer to down layer.

Pre-requisites for installation

• GI pipr ¾

• PVC pipe(1)

• Earth pit

• Charcoal

• Bentonate powder

In the earthening system, the ground electrode provides physical

connection to the mass of the earth and negative conductor is

24
used to deliver faulty current to it. In the lightening protection,
the role of the earthening system is to dissipate the lightening
current into the earth as quick as possible whilst minimizing the
ground potential rise and maximizing the potential fall off from
the current injection pit.

Bentonate powder and charcoal provides conductivity to the

earth. It should be noted that the cable should not be bent
sharply to a ‘U’OR ‘V’ formation at any point. The cable should run
horizontally or downward to the ground. Coppers should not be
used along side with aluminum roofing.

3.7 EARTHING PIT

Earthing resistance of an electrode is dependent on several

factors including; Soil resistance, Contact resistance of the
electrode to the earth, Resistance of the rods couplers and
connection.

Items needed for the construction of earth pit

• Rod material

• Couplers

• Driving equipments

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 • Wires

Installation ground rods should be 10-12 foot long. The couplers

should be used to couple the rod together in such a way as to
limit soil contact with the surface of the additional rods. Only the
first rod will maintain a soil contact. Mechanical drivers are
necessary to drive the rods deep into the ground; however, the
rod material coupler designed must be able to withstand the force
necessary to drive the rod into the sub-soils. To maintain full rod
to soil contact a slurry mixture of sodium betonite (naturally
occurring clay) is injected into the coupler void as the rods are
installed. This provides conductive material between the rod
surface and the soil over the depth of the rod. Electrode depth of
30-60feet are more effective and practical than that of 8-10 foot
because resistance of a shallow electrode will vary greatly as
seasonal conditions changes. Due to the high earth resistance,
the typical shallow electrode is unable to maintain an electrical
system at earth potential during transient voltage conditions of
lighting. While deep installed electrodes provides stable
resistance of less than 5 ohms.

3.8 CONSTRUCTION OF AN EARTH PIT

Before an earth pit is constructed, the follow points must be taken

into consideration.

i. The location of the pit should be such where the soil has
reasonable chances of becoming moist. This is because low earth

26
resistance is required to give effective earthling protection to
electrical fittings and a moist soil has such quality.

ii. If possible earth plates or pipes should be located near water

tap, water drains, or rain water pipes.

iii. Earth plates and earth wires must be of the same metal.

iv. Wood coal powder (charcoal) and salt must be filled in the
earth pit around the earth pipe or plate.

v. the position of the earth plate or pipe when fixed should be

clear from all building foundations.

vi. A masonry enclosure should be made over earth pit.

vii. Entrance, pavement and roads are definitely avoided for

locating the earth pit.

vii. Inside the building, in addition to all electrical appliances, all

switches boxes etc. should be earthed too.

CHAPTER FOUR

CONCLUSION

4.0 Skills Acquired

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 By virtue of this training I received, I have acquired the
following skills from my SIWES work place.

• I got a firsthand knowledge of some electrical industrial

equipment like the grinding cutting machine, industrial
generating set, electrical mobile panels, circuit breakers,
miller welding machines etc. Not only was I exposed to this
equipments, I learnt the principles with which they operate
in.

• I learnt the proper use of electrical tools such as the AVO

meter, screw drives, spanners, cutting machines etc.

• I was privileged to attend a number of tool boxes, safety

briefings. This enlightened me a lot on the risks and hazards
involved in the electrical world

• Ability to work effectively in a team and to communicate

effectively with others in related field. It also gave me the
opportunity to learn about good work ethics and good
interpretation and communication skills.

My industrial training has positively contributed to my training

as a future electrical/electronic engineer. It helped me broaden
my view on what is expected of me as a prospect engineer.

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4.1 Problems encountered my SIWES.

1. One of the major problems I encountered was getting an

ideal industrial placement. Ideal the sense that the company
suits with course of my study. As a result of this, I was forced
out of frustration to settle for something close to what is
needed(that is, going to company that does something close
or related to my course of study)

2. At the cause of my training, I was not closely supervised by

neither university nor industry based supervisor. I was not
given project or research to carry out and this slowed down
my learning process.

4.2 Ways of improving the SIWES programs

1. The SIWES management should make provision for

automatic placement of students in related industries.

2. Institutions and SIWES management should provide

effective supervision of students during then period of
industrial training experience.

3. T he SIWES management should go through the federal

government to make sure all the industries are involved in
providing effective industrial training opportunities for
students and also ensure that they are given benefits.

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4.3 Advice For Future Participants

1. Students should have in mind the main aim of the SIWES

and offer themselves better alternatives rather than
settling for anything. Better alternatives in the sense that,
instead of just working in any organization for the sole
purpose of getting money, they should enroll in
institutions that will impact more practical knowledge
even if they have to pay for it.

2. They should also start their placement application on

time, so that they can be attached on time.

3. They should learn the art of getting involved by observing

earnestly, asking question, carrying out assignments and
tasks judiciously, because that is basically the only way
they can acquire true knowledge.

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