Makerere University
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MAKERERE UNIVERSITY FACULTY OF TECHNOLOGY DEPARTMENT OF ELECTRICAL ENGINEERING INDUSTRIAL TRAINING REPORT BY NSUBUGA MANSEN REG. NO.: 08/U/3080/PSA COURSE: Bsc. ELECTRICAL ENGINEERING TRAINING FIRM: ROOFINGS LIMITED 02/06/2010 - 10/07/2010 SUPERVISORS: MR.PATRICK MUGISHA DEPARTMENT OF ELECTRICAL ENGINEERING MAKERERE UNIVERSITY Sign«««««««««««««.. Date«««««««««««««.. MR. MATOVU AFZARI SENOIR MAINTENANCE MANAGER ROOFINGS LIMITED Sign«««««««««««««.. Date«««««««««««««... Acknowledgement First and foremost, I would like to thank the University for the Provision of the program of internship, this is an important program in the development of an effective engineer. My gratitude also extends to Mr. Patrick Mugisha my supervisor for his continued guidance and wisdom that he has generously offered to me. Secondly, my gratitude goes to Roofings limited for enrolling me for training in their company, it has been through this opportunity that I have discovered my self as an engineer in power. I also acknowledge the guidance offered to me during my training officer Engineer Matovu Afzal. Lastly, I would like to thank my parents for continued support both financially and emotional. I can¶t express how much grateful I am to them. i Dedication This work is dedicated to all the people I have worked with, those who have helped develop my practical skills in one way or the other and to my caring parents. ii Preface Chapter one discusses two items. The first one being the program of industrial training as arranged by the university, and the objectives of industrial training. Secondly, chapter one discusses the profile of Roofings Company in which the reader is introduced to the management structure of Roofings. It also discusses the various raw materials used in the production of their products. And finally, the machinery used the production of various products. Chapter two Talks about various installation activities we executed plus the relevant theory behind the work done. The work discussed ranges from the installation work in the substation to the wiring of the new production bay. Among the theory discussed are the substation components such transformers etc. Chapter two goes ahead to discuss the programmable logic controllers in details. Chapter three goes into the maintenance field by first discussing the theory about motors, discuss the various tools in troubleshooting and maintenance of motors. It goes ahead to discuss all the possible faults in motors and the recommended procedures for troubleshooting the motors. Chapter four discusses the acknowledgements to the training to the various respects. It further discusses the challenges I experienced during my training, the potential risks and hazards I encountered and the possible measures taken by the company to cub and reduce on these hazards. The chapter finally ends with a conclusion and my personal opinion about the training. iii Table of Contents Contents Acknowledgement .................................................................................................................................... i Dedication ............................................................................................................................................... ii Preface ................................................................................................................................................... iii Table of Contents ................................................................................................................................... iv List of Figures ........................................................................................................................................ vii List of Tables ......................................................................................................................................... viii CHAPTER ONE: ......................................................................................................................................... 1 INTRODUCTION ....................................................................................................................................... 1 1.1 INDUSTRIAL TRAINING.................................................................................................................. 1 1.2 COMPANY PROFILE....................................................................................................................... 2 1.2.1 Company Background ............................................................................................................ 2 1.2.2 Production Sections and Machinery ...................................................................................... 4 CHAPTER 2: ELECTRICAL INSTALLATIONS ................................................................................................. 8 2.1 INSTALLATION ASSEMBLY BLOCK DIAGRAM ................................................................................. 8 2.2 DIAGRAM SHOWING THE ONE LINE DIAGRAM OF THE INSTALLED SUBSTATION ........................... 9 2.3 THE SUBSTATION ...................................................................................................................... 10 2.3.1 Overhead Bus Bars............................................................................................................... 10 2.3.2 Voltage Transformer ............................................................................................................ 10 2.3.3 Protective devices................................................................................................................ 11 2.3.4 Power Transformers ............................................................................................................ 12 2.3.5 Earthing of the Substation ................................................................................................... 14 2.3.6 Practical Work Done ............................................................................................................ 14 2.4. THE LV MAIN SWITCH BOARD .................................................................................................... 19 2.4.1 Purpose of the Main Switch Board ..................................................................................... 19 2.4.2 Components of the Main Switch Board ............................................................................... 19 2.4.3 Practical Work Done ............................................................................................................ 22 2.5 THE DISTRIBUTION CABINET ....................................................................................................... 24 2.5.1 Purpose of the distribution cabinet ...................................................................................... 24 iv 2.5.2 Components of the distribution cabinet ............................................................................... 25 2.6 WIRING OF THE PRODUCTION BAY ............................................................................................. 27 2.6.1 Practical work done ............................................................................................................. 28 2.7 MOTOR SPECIFICATION AND CONNECTION ................................................................................ 30 2.7.1 Water Circulation Unit ......................................................................................................... 30 2.7.2 Entry Coil Car ....................................................................................................................... 30 2.7.2 Slitter Motor ........................................................................................................................ 30 2.7.4 Exit Coil Car ......................................................................................................................... 31 2.7.5 Entry Hydraulic Power Unit .................................................................................................. 31 2.7.6 Exit Hydraulic Power Unit .................................................................................................... 32 2.8.0 POWER SUPPLY IN THE MAIN PRODUCTION BAY ..................................................................... 33 2.8.1 The one line diagram of power distribution in the production bay ....................................... 33 2.8.2 Generator ............................................................................................................................ 35 CHAPTER 3: ELECTRICAL MAINTENANCE ................................................................................................ 37 3.1 MOTORS ...................................................................................................................................... 37 3.1.1 Types of Motors .................................................................................................................... 37 3.1.2 Methods of Starting Electric Motors .................................................................................... 41 3.1.3 Factors Considered when selecting a starter ........................................................................ 44 3.1.4 Tools Used In Troubleshooting Motors ................................................................................ 45 3.1.5 Procedure for Trouble Shooting Single Phase Motors .......................................................... 47 3.1.6 Trouble Shooting guide for Single phase Motors .................................................................