Siwes) Training Programme (January 2018 – July 2018) at Galant Investment Ltd

REPORT OF STUDENT INDUSTRIAL WORK EXPERIENCE SCHEME (SIWES) TRAINING PROGRAMME (JANUARY 2018 – JULY 2018) AT GALANT INVESTMENT LTD. BY NNADI VICTOR CHINEDU 14CM017032 MECHANICAL ENGINEERING, MECH ENG DEPARTMENT. COVENANT UNIVERSITY BEING A REPORT SUBMITTED TO THE DEAN COLLEGE OF ENGINEERING IN PARTIAL FULFILMENT OF THE REQUIREMENTS FOR MCE 429 DEAN COE: PROF. BOLU CHRISTIAN AMAECHI JULY 2018

Dedication To God for granting me an internship placement this year, for the strength and preservation to work for the duration of the internship.

Acknowledgements Firstly, I thank God for granting me an internship placement this year, for the strength and preservation to work for 6 months. It was a pleasant experience. I thank the management of Galant Investment LTD for accepting me as an intern and giving me the tools and permission to work and gain experience. I thank Engr. Taiwo Ajose, the freelance generator specialist for impacting me technically, morally and spiritually, and his wife and children for welcoming me into their home throughout the period I worked there. I thank the management of Covenant University for organizing the program. I thank the staff concerned for the prior 4 year theoretical training that made the process of getting hands on training a breeze. I thank my supervisor for taking out time to observe and carefully validate my operations at GIL. I also thank my fellow interns for being good company to me both physically and virtually.

Contents Dedication ...... 1 Acknowledgements ...... 2 Galant Investment LTD...... 5 Chapter 1 – Introduction, participation and work done...... 6 Chapter 2 – New Experience gained...... 18 Chapter 3 – Challenges encountered by student...... 39 Chapter 4 – Observations & Contributions ...... 40 Chapter 5 - Conclusion ...... 41 Chapter 6 - Challenges Observed as being faced by the SIWES Industry-based Firm ...... 42 Related Diagrams ...... 44

Abstract INTRODUCTION I worked as an intern at Galant Investment Limited for 6 months from January to July 2018. During my stay there I gained a lot of experience repairing, installing, and purchasing inverters, solar panels, batteries and generators. The focus was on learning about combustion engines and how it worked and learning about practical electrical and electronics engineering. OBJECTIVE The objectives of this report are - To highlight my participation at GIL, and the experience I gathered. - To highlight the challenges I encountered - To highlight my observations and contributions to the company. METHODOLOGY The document starts off with an introduction of the company, GEN Galant Investment LTD, followed by a detail-rich list of the various kinds of work I participated in. This is followed by a chapter that highlights my experience gained at GIL, here I explain what I learnt on the field, in lectures and through personal study inspired by the work done. Thereafter, a chapter that highlights the challenges I faced trying to get used to the work and become a more valuable intern, then a chapter that contains my observations and contributions, then a brief conclusion. The report was then rounded off with the challenges I observed has been faced by the company during the period of my attachment. All related diagrams were intelligently embedded in the body of the document to aid a better reading experience.

Galant Investment LTD. I started working at Galant Power Solutions LTD on January 29, 2018 Galant Power Solutions is a Nigerian energy company with a daring vision to use the power of the sun to bring 24/7 electricity supply to Nigerian/African homes at an affordable cost, one home at a time. Staff Introduction I was introduced to the concept of the business. I was given a tour around the facility and introduced to the tools I would need. We had a sit down meeting to discuss about my industrial training program and I was introduced to the areas of operation that I would be trained in. We concluded that for the first three months, I would be attached with Engr. Taiwo Ajose, under whom I would learn how to install, maintain and repair portable electrical generators of various sizes. And for the remaining time of the program, I would come back to the head office where I would learn practical electrical works such as household electrical wiring, electricity distribution theory, the use of electrical engineering tools, installation, maintenance and repair of inverters, solar panels and deep cycle batteries. “Modern mechanical systems hardly can do without embedded electrical systems. Hence a good mechanical engineer should also be well grounded in Electrical and electronics systems knowledge, to be able to safely design a complete modern mechanical system” - Engr. Godwin Nnadi, President of Galant Power Solutions.

Chapter 1 – Introduction, participation and work done.

1.1 PPE DISPENSARY I was given the following personal protective equipment 1. Hand Gloves 2. Overalls 3. Helmet 4. Safety Googles 5. Ear Mufflers 6. Safety Boots 1.2 INTRODUCTION TO BASIC MEASUREMENT TOOLS AND PRINCIPLES I was taught how to use a tape rule, Vernier caliper, micrometer screwguage meter rule and I was introduced to the Sounding tape used to measure the depth of liquids. I was made to understand that other more complex tools would be revealed to me during the course of my training. 1.3 TRAINING ON THE USE OF PERSONAL PROTECTIVE EQUIPMENT I was thought about the use of the various PPEs I was issued. 1. Hand Gloves: The workplace can create many hazards for your hands, whether from chemicals, cuts or burns. Industrial safety work gloves are designed to reduce hand injuries in complex work environment without hindering the user’s overall dexterity in the field. They are useful during welding operations and when working with electricity. 2. Overalls: (also called dungarees), usually made denim or chino cloth. It is a type of garment used as a protective clothing when working. It protects your body and garment from harmful and harmless liquid spillages. It is also designed to not have hanging or draping parts that can get entangled in rotating machines. 3. Helmet: This is a firm of protective gear worn to protect the head from injuries. It aids the skull in protecting the human brain. Useful when working in an area that is prone to fallen objects. 4. Safety Googles: Googles or Safety Glasses are forms of protective eye wear that usually enclose or protect the area surrounding the eye in order to prevent particulates, water or chemical from striking the eyes. In welding shaded googles are used to protect the eyes against flares. 5. Ear mufflers: These are a style of hearing protection that fit around the external ear used to reduce the transmission of sound from entering the ear canal. Nosie is reduced to a safer intensity level protecting against noise-induced hearing loss. The Occupational safety and Health Administration (OSHA) recommends the use of hearing protection

devices HPD when an employee is exposed to an average noise intensity of 85DBA over an 8 hour shift. 6. Safety Boots: (Also known as steel toe boot or a steel capped boot or safety shoe) is a durable boot or shoe that has a protective reinforcement in the toe which protects the foot from falling objects.

1.4 DETAILED TRAINING ON SAFETY Safety was an integral and important part of operations at Galant Power Solutions. A whole week was used to train me thoroughly on good safety practice. Here are the safety practices that I was trained in. I was introduced to concepts such as Save Your Life, Work at height, Firefighting, working in confined spaces and working with electricity. 1.5 WORKING WITH NEW MEASURING INSTRUMENTS I was introduced to new measuring instruments like the AVOmeter, the Meger (for insulation resistance testing), clip-on ammeter, and the battery tester. 1.6 PORTABLE GENERATOR REPAIRS, PURCHASE, INSTALLATION AND MAINTENANCE. From February 12th, I was sent to be attached with Engr. Taiwo Ajose, a Mechanical Engineer with over 20 years of experience of working with generators of various sizes, for a period of 3 months. Throughout the period, we solved a ton of generator problems in and around FESTAC Town, ranging from repairs, purchase assistance, installation and maintenance. We were opportune to solve over 100 problems related to generators during my stay. Below, I have highlighted a few of the challenges we encountered and how we diagnosed and solved them:- Case 1; Date: February 12; Location: 2nd Avenue, FESTAC Town. Work Nature: Preventive Maintenance (PM) and Corrective Maintenance (CM) Generator type: GX160 Elemax Problem as described by client: The client did not lay any complaints. He only required PM procedures Diagnosis: Apart from the PM that was requested, we noticed that some parts of the silencer system were broken and they were vibrating against each other causing an abnormal operation noise. Solution: We carried out complete PM procedures 1. We flushed the carburetor

2. We decarbonized the cylinder head and the piston head 3. The spark plug was cleaned 4. We drained and replaced the engine oil with Forte SAE 40 oil, as recommended for our clime. We also welded the broken parts of the silencer and this fixed the vibrational noise problem.

Damaged Silencer housing – It was sent for welding.

Case 2; Date: April 13; Location: 41 rd., FESTAC Town. Work Nature: Corrective Maintenance (CM) Generator type: SUMEC FIRMAN Problem as described by client: Smoking Generator and other problems. Diagnosis: We prescribed that the piston and rings be changed to achieve satisfactory working mode.

Solution: We had to transport the generator to our workshop. 1. We dismantled the generator set. 2. We documented and ordered the parts that needed to be replaced 3. We ground the inlet and outlet valves and valve seats, and decarbonized the entire cylinder head. 4. We assembled the set with the new parts well installed. 5. We put in new engine oil (SAE 40) and put in new fuel and tested it to ensure that it worked smoothly. 6. We delivered the set back to the client.

Decarbonizing the cylinder head of the SUMEC FIRMAN

Case 3; Date: March 23; Location: Ago. Work Nature: Corrective Maintenance (CM) Generator type: Honda Problem as described by client: The generator operation noise was very unsatisfactory. Diagnosis: We discovered that the ball bearing at the coil side had worn out. The balls rolling abnormally against each other was the cause of the noise.

Solution: We had to disassemble the generator set. We highlighted the list of parts that we wanted to replace. Upon receiving approval from the client, we ordered the parts. We had to detach the stator and rotor coils, in order to remove the damaged bearing since it is mated with the rotor coil. During the operation, due to the missed strike of a hammer, some marks were indented on the rotor coil brush sleeve. We also had to file it back into a leveled smooth surface.

Using a small sand paper to file the brush sleeve of the rotor to achieve a smooth surface.

Case 4; Date: February 23; Location: Deeper Life Church, 23 rd, FESTAC Town. Work Nature: Corrective Maintenance (CM) Generator type: GX160 Problem as described by client: Damaged AC socket Diagnosis: Probably due to electricity surge, or twist and turns, the AC socket of the generator had worn out completely and could no longer hold the plug within it. Solution: We carried out complete CM procedures 1. We replaced the AC sockets

My boss removing the old burnt out socket.

Case 5; Date: April 2; Location: Construction site at 24 rd., FESTAC Town. Work Nature: Problem Inspection and Corrective maintenance. Generator type: Honda Problem as described by client: The set did not supply electricity. Diagnosis: At first we thought that the problem was either with the AVR, or the coil brush. Solution: Our first attempt of solving the problem was to purchase a new AVR. We tested this and it didn’t remedy the problem. Interestingly, we immediately discovered that the circuit breaker trigger switch was switched on. This meant that the generator had no issue at all, it just needed this trigger to be deactivated.

The new AVR we purchased when we thought that it was the problem.

Case 6; Date: April 5; Location: 21 rd. FESTAC Town. Work Nature: Purchase and installation. Generator type: Elemax GX 160 Solution: We purchased and installed a generator set for the client.

The dealer shop where we purchased the generator set.

Case 7; Date: March 16; Location: 208 rd. B close, FESTAC Town. Work Nature: Corrective Maintenance (CM) Generator type: Honda GX160 Problem as described by client: Oil leak from crank case during operation. Diagnosis: The oil seal had worn out. Solution: We disassembled mechanical assembly and removed oil seal. We ordered for a new oil seal and reinstalled it.

Old oil seal New oil seal installed

Case 8; Date: April 11; Location: 23 rd. I close, FESTAC Town. Work Nature: Plant Inspection Generator type: Diesel Generator Solution: The client requested that we drain the diesel and check for dirt. It was clean and we simply refilled the tank. I was also shown how to service the generator if the need arises.

Cross section of the diesel engine.

Due to the word limit of this document, I only highlighted a few of the interesting works I did on generators. For the complete list, please see my logbook or the more detailed report attached with this one.

1.7 ELECTRICAL AND ELECTRONICS TRAINING From 14th of May, I returned to Galant Investment LTD, to continue work in the Electrical and Electronics section. Here I participated in a series of lectures on Electrical and Electronics engineering, we did a household electricity consumption simulation, we also practiced house hold electrical wiring using a junction box, I assisted in the installation of inverters and solar panels. 1. House hold electricity consumption: We imagined a typical bungalow in Lagos state and tried to deduce n estimate of its power consumption.

2. Lectures on how electricity is distributed in the home – the Distribution Board.

3. Household electrical wiring practice using a junction box

4. Inverter and solar panel installation: I assisted in the installation of inverter, solar panels, solar charge controller and batteries for one of GIL’s clients.

These and other related activities were carried out in this section.

Chapter 2 – New Experience gained.

2.1 DIVERSE TYPES OF CHALLENGES ENCOUNTERED RELATED TO PORTABLE GENERATORS. I was privileged to work on diverse problems as opposed to routine ones, therefore I was able to encounter, diagnose and solve different kinds of problems related to portable generators. 2.2 EXPOSURE TO NEW CONCEPTS LIKE STROBOSCOPY STROBOSCOPY Stroboscopy is an effect in which a cyclically rotating object is made to appear stationary. When working with rotating machineries in a workshop. It is a good safety measure to avoid stroboscopy as it would be very dangerous to come in contact with a rotating machine without prior awareness. A good practice is to use an incandescent bulb as against a fluorescent light in the work shop. If you have to use fluorescent bulbs, they should all be connected in different phases. 2.3 HOUSEHOLD WIRING We used a junction box to practice the most native form of electrical wiring. 2.4 HOW ELECTRICITY TRANSMISSION WORKS I was exposed in details to the way electricity is generated and transmitted to homes, offices and industries. 2.5 LOCK AND TAG Lockout-tagout (LOTO) or lock and tag is a safety procedure which is used in industry and research settings to ensure that dangerous machines are properly shut off and not able to be started up again prior to the completion of maintenance or repair work. It requires that hazardous energy sources be "isolated and rendered inoperative" before work is started on the equipment in question. The isolated power sources are then locked and a tag is placed on the lock identifying the worker who placed it. The worker then holds the key for the lock ensuring that only he or she can remove the lock and start the machine. This prevents accidental startup of a machine while it is in a hazardous state or while a worker is in direct contact with it. Lockout-tagout is used across industries as a safe method of working on hazardous equipment and is mandated by law in some countries.

2.6 BATTERY TESTING I was trained on how to use a battery tester to know the health of battery. 2.7 INVERTER INSTALLATION I was theoretically trained on how inverters are installed and how they are wired such that they select only the loads of the premises that they can bear. 2.8 LAYING OF SOLAR PANELS I assisted in the laying of solar panels for a client of ours. I got to understand the different precautions that needed to be observed to have a successful installation (e.g, avoiding direct contact of the positive and negative terminals, the adequate exposure of the panels to the sun, required direction or bearing of lay, Etc.) 2.9 SOLAR CHARGE CONTROLLER CONFIGURATION I learnt how to connect and configure the solar charge controller which helps to monitor and control the charge of the batteries for the inverter. 2.10 TRADE STRATEGIES, TRICKS, AND PRICING. Since it was a small organization, we also had to handle the business aspects ourselves. I was thought about the pricing system, the strategies that are used to succeed in the trade, the importance of relationships and how to build and keep them and the tricks and shortcuts that are used by masters of the trades. 2.11 NEW MEASURING INSRUMENTS I was also exposed to new measuring instruments that I had never worked with before. AVOMETER

AVOmeter is a British trademark for a line of multimeters and electrical measuring instruments; the brand is now owned by the Megger Group Limited. The first Avometer was made by the Automatic Coil Winder and Electrical Equipment Co. in 1923, and measured direct voltage, direct current and resistance. Possibly the best known multimeter of the range was the Model 8, which was produced in various versions from May 1951 until 2008; the last version was the Mark 7. The multimeter is often called simply an AVO, because the company logo carries the first letters of 'amps', 'volts' and 'ohms'. The design concept is due to the Post Office engineer Donald Macadie, who at the time of the introduction of the original AVOmeter in 1923 was a senior officer in the Post Office Factories Department in London. Megger | Working Principle, Types, Uses of Megger

What is Megger? Insulation resistance IR quality of an electrical system degrades with time, environment condition, i.e., temperature, humidity, moisture and dust particles. It also gets impacted negatively due to the presence of electrical and mechanical stress, so it’s become very necessary to check the IR (Insulation resistance) of equipment at a constant regular interval to avoid any measure fatal or electrical shock.

Uses of Megger The device enable us to measure electrical leakage in wire, results are very reliable as we shall be passing electric current through device while we are testing. The equipment basically uses for verifying the electrical insulation level of any device such as motors, cables, generators, windings, etc. This is a very popular test being carried out since very long back. Not necessary it shows us exact area of electrical puncture but shows the amount of leakage current and level of moisture within electrical equipment/winding/system. Types of Megger

This can be separated into mainly two categories:- 1. Electronic Type (Battery Operated) 2. Manual Type (Hand Operated) But there is another types of megger which is motor operated type which does not use battery to produce voltage it requires external source to rotate a electrical motor which in turn rotates the generator of the megger.

Electronic Type Megger Important parts:- 1. Digital Display: - A digital display to show IR value in digital form. 2. Wire Leads: - Two no’s of wire leads for connecting megger with electrical external system to be tested. 3. Selection Switches: - Switches use to select electrical parameters ranges. 4. Indicators: - To indicates various parameters status i.e. On-Off. For Example Power, hold, Warning, etc. Note: - Above construction is not similar for every megger, it difference appears manufacture to manufacture but basic construction and operation are same for all. Advantages of Electronic Type Megger

 Level of accuracy is very high.

 IR value is digital type, easy to read.

 One person can operate very easily.

 Works perfectly even at very congested space.

 Very handy and safe to use. Disadvantages of Electronic Type Megger

 Require an external source of energy to energies i.e. Dry cell.

 Costlier in market. Hand Operated Megger

Important parts: - Analog display: - Analog display provided on front face of tester for IR value recording. Hand Crank: - Hand crank used to rotate helps to achieve desired RPM required generate voltage which runs through electrical system. Wire Leads: - Used same as in electronic tester i.e. for connecting tester with electrical system. Advantages of Hand Operated Megger 1. Still keeps important in such high-tech world as it’s an oldest method for IR value determination. 2. No external source required to operate. 3. Cheaper available in market. Disadvantages of Hand Operated Megger

1. At least 2 person required to operate i.e. one for rotation of crank other to connect megger with electrical system to be tested. 2. Accuracy is not up to the level as it’s varies with rotation of crank. 3. Require very stable placement for operation which is a little hard to find at working sites. 4. Unstable placement of tester may impact the result of tester. 5. Provides an analog display result. 6. Require very high care and safety during use of the same. Construction of Megger Circuit Construction features:-

1. Deflecting and Control coil: Connected parallel to the generator, mounted at right angle to each other and maintain polarities in such a way to produced torque in opposite direction. 2. Permanent Magnets: Produce magnetic field to deflect pointer with North-South pole magnet. 3. Pointer: One end of the pointer connected with coil another end deflects on scale from infinity to zero. 4. Scale: A scale is provided in front-top of the megger from range ‘zero’ to ‘infinity’, enable us to read the value.

5. D.C generator or Battery connection: Testing voltage is produced by hand operated DC generator for manual operated Megger. Battery / electronic voltage charger is provided for automatic type Megger for same purpose. 6. Pressure Coil Resistance and Current Coil Resistance: Protect instrument from any damage because of low external electrical resistance under test. Working Principle of Megger

 Voltage for testing produced by hand operated megger by rotation of crank in case of hand operated type, a battery is used for electronic tester.

 500 Volt DC is sufficient for performing test on equipment range up to 440 Volts.

 1000 V to 5000 V is used for testing for high voltage electrical systems.

 Deflecting coil or current coil connected in series and allows flowing the electric current taken by the circuit being tested.

 The control coil also known as pressure coil is connected across the circuit.

 Current limiting resistor (CCR and PCR) connected in series with control and deflecting coil to protect damage in case of very low resistance in external circuit.

 In hand operated megger electromagnetic induction effect is used to produce the test voltage i.e. armature arranges to move in permanent magnetic field or vice versa.

 Where as in electronic type megger battery are used to produce the testing voltage.

 As the voltage increases in external circuit the deflection of pointer increases and deflection of pointer decreases with a increases of current.

 Hence, resultant torque is directly proportional to voltage and inversely proportional to current.

 When electrical circuit being tested is open, torque due to voltage coil will be maximum and pointer shows ‘infinity’ means no shorting throughout the circuit and has maximum resistance within the circuit under test.

 If there is short circuit pointer shows ‘zero’, which means ‘NO’ resistance within circuit being tested. Work philosophy based on ohm-meter or ratio-meter. The deflection torque is produced with megger tester due to the magnetic field produced by voltage and current, similarly like ‘Ohm's Law’. The torque of the megger varies in a ration with V/I, (Ohm's Law:- V = IR or R = V/I). Electrical resistance to be measured is connected across the generator and in series with deflecting coil. Produced torque shall be in opposite direction if current supplied to the coil. 1. High Resistance = No Current: - No current shall flow through deflecting coil, if resistance is very high i.e. infinity position of pointer.

2. Small Resistance = High Current :- If circuit measures small resistance allows a high electric current to pass through deflecting coil, i.e. produced torque make the pointer to set at ‘ZERO’. 3. Intermediate Resistance = Varied Current: - If measured resistance is intermediate, produced torque align or set the pointer between the range of ‘ZERO to INIFINITY’. Connection Diagram of Megger for Testing

TACHOMETER A tachometer (revolution-counter, tach, rev-counter, RPM gauge) is an instrument measuring the rotation speed of a shaft or disk, as in a motor or other machine. The device usually displays the

25 revolutions per minute (RPM) on a calibrated analogue dial, but digital displays are increasingly common. The word comes from Greek ταχος (tachos "speed") and metron ("measure"). Essentially the words tachometer and speedometer have identical meaning: a device that measures speed. It is by arbitrary convention that in the automotive world one is used for engine and the other for vehicle speed. In formal engineering nomenclature, more precise terms are used to distinguish the two.

ELECTRICTY METER An electricity meter, electric meter, electrical meter, or energy meter is a device that measures the amount of electric energy consumed by a residence, a business, or an electrically powered device. Electric utilities use electric meters installed at customers' premises for billing purposes. They are typically calibrated in billing units, the most common one being the kilowatt hour (kWh). They are usually read once each billing period. When energy savings during certain periods are desired, some meters may measure demand, the maximum use of power in some interval. "Time of day" metering allows electric rates to be changed during a day, to record usage during peak high-cost periods and off-peak, lower-cost, periods. Also, in some areas meters have relays for demand response load shedding during peak load periods.

CLIP-ON AMMETER In electrical and electronic engineering, a current clamp or current probe is an electrical device with jaws which open to allow clamping around an electrical conductor. This allows measurement of the current in a conductor without the need to make physical contact with it, or to disconnect it for insertion through the probe. Current clamps are typically used to read the

26 magnitude of alternating current (AC) and, with additional instrumentation, the phase and waveform can also be measured. Some clamps meters can measure currents of 1000 A and more. Hall Effect and vane type clamps can also measure direct current (DC).

Types of current clamp Current transformer A common form of current clamp comprises a split ring made of ferrite or soft iron. A wire coil is wound round one or both halves, forming one winding of a current transformer. The conductor it is clamped around forms the other winding. Like any transformer this type works only with AC or pulse waveforms, with some examples extending into the megahertz range. When measuring current, the subject conductor forms the primary winding and the coil forms the secondary. This type may also be used in reverse, to inject current into the conductor, for example in electromagnetic compatibility susceptibility testing to induce an interference current. Usually, the injection probe is specifically designed for this purpose. In this mode, the coil forms the primary and the test conductor the secondary. Iron vane In the iron vane type, the magnetic flux in the core directly affects a moving iron vane, allowing both AC and DC to be measured, and gives a true root mean square (RMS) value for non- sinusoidal AC waveforms. Due to its physical size it is generally limited to power transmission frequencies up to around 100 Hz.

An electrical meter with integral AC current clamp is known as a clamp meter, clamp-on ammeter or tong tester. A clamp meter measures the vector sum of the currents flowing in all the conductors passing through the probe, which depends on the phase relationship of the currents. Only one conductor is normally passed through the probe. In particular if the clamp is closed around a two-conductor cable carrying power to equipment, the same current flows down one conductor and up the other; the meter correctly reads a net current of zero. As electrical cables for equipment have both insulated conductors (and possibly an earth wire) bonded together, clamp meters are often used with what is essentially a short extension cord with the two conductors separated, so that the clamp can be placed around only one conductor of this extension. A relatively recent development was a multi-conductor clamp meter with several sensor coils around the jaws of the clamp. This could be clamped around standard two- or three-conductor single-phase cables to provide a readout of the current flowing through the load, with no need to separate the conductors. The reading produced by a conductor carrying a very low current can be increased by winding the conductor around the clamp several times; the meter reading divided by the number of turns is the current, with some loss of accuracy due to inductive effects. Clamp meters are used by electricians, sometimes with the clamp incorporated into a general purpose multimeter. It is simple to measure very high currents (hundreds of amperes) with the appropriate current transformer. Accurate measurement of low currents (a few milliamperes) with a current transformer clamp is more difficult. The range of any given meter can be extended by passing the conductor through the jaw multiple times. For example a 0–200 A meter can be turned into a 0–20 A meter by winding the conductor 10 times around the jaw's core. The vane is usually fixed directly to the display mechanism of an analogue (moving pointer) clamp meter. Hall Effect The Hall Effect type is more sensitive and is able to measure both DC and AC, in some examples up to the kilohertz (thousands of hertz) range. This type was often used with oscilloscopes, and with high-end computerized digital multimeters, however, they are becoming common place for more general use. Rogowski coil Resembling a current clamp in appearance and function is the Rogowski coil current sensor. This coreless transformer is used in clamp meters and power monitoring loggers. It has the advantage of better linearity, having no core to saturate, it can be made flexible, and does not require any magnetic or electrical contact at the opening end. The Rogowski coil gives a voltage proportional to the rate of change of current in the primary cable, so more signal processing is needed before the sensed values can be displayed.

An electrical meter with integral AC current clamp is known as a clamp meter, clamp-on ammeter or tong tester.

CLAMP METER A clamp meter measures the vector sum of the currents flowing in all the conductors passing through the probe, which depends on the phase relationship of the currents. Only one conductor is normally passed through the probe. In particular if the clamp is closed around a two-conductor cable carrying power to equipment, the same current flows down one conductor and up the other; the meter correctly reads a net current of zero. As electrical cables for equipment have both insulated conductors (and possibly an earth wire) bonded together, clamp meters are often used with what is essentially a short extension cord with the two conductors separated, so that the clamp can be placed around only one conductor of this extension. A relatively recent development was a multi-conductor clamp meter with several sensor coils around the jaws of the clamp. This could be clamped around standard two- or three-conductor single-phase cables to provide a readout of the current flowing through the load, with no need to separate the conductors. The reading produced by a conductor carrying a very low current can be increased by winding the conductor around the clamp several times; the meter reading divided by the number of turns is the current,] with some loss of accuracy due to inductive effects. Clamp meters are used by electricians, sometimes with the clamp incorporated into a general purpose multimeter. It is simple to measure very high currents (hundreds of amperes) with the appropriate current transformer. Accurate measurement of low currents (a few milliamperes) with a current transformer clamp is more difficult. The range of any given meter can be extended by passing the conductor through the jaw multiple times. For example a 0–200 A meter can be turned into a 0–20 A meter by winding the conductor 10 times around the jaw's core. Less-expensive clamp meters use a rectifier circuit which actually reads mean current, but is calibrated to display the RMS current corresponding to the measured mean, giving a correct RMS reading only if the current is a sine wave. For other waveforms readings will be incorrect; when these simpler meters are used with non-sinusoidal loads such as the ballasts used with fluorescent lamps or high-intensity discharge lamps or most modern computer and electronic equipment, readings can be quite inaccurate. Meters which respond to true RMS rather than mean current are described as "true RMS". Typical hand-held Hall effect units can read currents as low as 200 mA, and units that can read down to 1 mA are available. The Columbia tong test ammeter (illustrated) is an example of the iron vane type, used for measuring large AC currents up to 1000 amperes. The iron jaws of the meter direct the magnetic field surrounding the conductor to an iron vane that is attached to the needle of the meter. The

29 iron vane moves in proportion to the strength of the magnetic field, and thus produces a meter indication proportional to the current. This type of ammeter can measure both AC and DC currents and provides a true RMS current measurement of non-sinusoidal or distorted AC waveforms. Interchangeable meter movements can be installed in the clamping assembly to provide various full-scale current values up to 1000 amperes. The iron vane is in a small cylinder that is inserted in a space at the hinged end of the clamp-on jaws. Several jaw sizes are available for clamping around large conductors and bus bars up to 4 1⁄2 inches (110 mm) wide. As the illustration shows, the scale is very non-linear and unsuitable for measuring low currents, with currents of less than half the full-scale deflection crammed into a short section of the dial. Power meter, energy analyzer Clamp probes are used with some meters to measure electrical power and energy. The clamp measures the current and other circuitry the voltage; the true power is the product of the instantaneous voltage and current integrated over a cycle. Comprehensive meters designed to measure many parameters of electrical energy (power factor, distortion, instantaneous power as a function of time, phase relationships, etc.), energy analyzers, use this principle. A single clamp is used for single-phase measurements; with an appropriate instrument with three clamps, measurements may be made on three-phase power systems.

2.12 SAVE YOUR LIFE It is important to note that life is the top priority in whatever activity you involve yourself in as an engineer. I was made to understand this very well in the safety training week at Galant Power Solutions. I was instructed that whatever be the challenge, I should save myself first. 2.13 WORKING AT HEIGHT The working height can be dangerous if safety precautions are not taken. Work requiring the use of ladder or scaffolding must be adorned with safety measures in order to eliminate as much risks to workers. Work at height is work in any place, including a place at, above or below the ground level, where a person would be injured if they fell from that place. Access and egress to a place of work can also be work at height. Examples of work activities that are classified as working at height. 1. Working on Trestles 2. Working on a flat roof 3. Erecting falsework or framework. 4. Working on a ladder 5. Working at ground level adjacent to an excavation 6. Working on formwork within an excavation 7. Working near or adjacent fragile materials. The work at height regulations require that:

1. All work at height is properly planned and organized 2. A risk assessment is carried out for all work conducted as height. 3. Appropriate work equipment is selected and used 4. People working at height are competent 5. Equipment used for work at height is properly inspected and maintained 6. Risks from fragile surfaces are properly controlled. The risk assessment should include a careful examination of what harm could be caused from working a height with a view of taking the effective steps to reduce the likelihood of the harm occurring, either through avoiding the activity or, where this is not reasonably practicable, by carrying it out in a safe manner using work equipment that is appropriate for the task and the level of risk. Exceptions Examples of where regulations do not apply include 1. Walking up and down a staircase in an office 2. Working in an office on the upper floors of a temporary accommodation. 3. Sitting in a chair 4. Work carried out by private individuals in their own homes where there is not a purpose for business or trade

2.14 FIRE FIRE DETECTION All work places should have arrangements for detecting fire. IS 3218 gives a basis for assessing what type of detection system will be appropriate for a work place and will also give guidance to its installation. Consideration must be given to any parts of the workplace where a fire could start and spread undetected. This could be a storage area or a basement that is not visited on a regular basis, or part of a workplace that has been temporarily vacated, for example at meal times. Fires that start and develop unnoticed can pose a serious danger to people in the workplace In most places where fire could develop for some time before being discovered, it is important to protect vital escape routes, particularly staircases with fire-resisting construction which may include fire-resisting doors. Installing an effective, reliable automatic fire detection system, linked to an effective fire warning system, can sometimes allow people to reassess the degree of structural fire protection required on escape routes.

FIRE WARNING

In almost all buildings, a suitable electrically operated fire warning system with manual call points positioned both in exit routes and adjacent to final exits should be installed. This should have sufficient sounders for the warning to be clearly heard throughout the workplace. The sound used as a fire warning should be distinct from other sounds in the workplace and where background noise levels are high or an employee has a hearing impairment, it may also be necessary to install a visual alarm such as a distinct flashing or rotating light. In more complex building s such as retail premises where the evacuation system is based on staged or phased evacuation, or where people are unfamiliar with the fire warning arrangements, the landlord or employer might consider installing a voice evacuation system. The system could form part of a public address and could give both fire warning signals and verbal instructions in the events of fire. EMERGENCY ESCAPE AND FIRE FIGHTING Escape routes should be kept clear of all obstructions. Generally, escape routes should be at least one meter wide. The escape route should lead to a place of safety, normally outside and away from the building. Doors on escape routes must always be available for use without the need of a key. When assessing the adequacy of the means of escape, you will need to take into account: 1. The findings of your fire risk assessment 2. The size of the workplace, its construction layout, contents and the number and width of the available escape routes. 3. The workplace activity, where people may be situated in the workplace and what they may be doing when a fire occurs 4. The number of people who may be present, and their familiarity with the workspace. 5. Their ability to escape without assistance.

2.15 WORKING IN A CONFINED SPACE Confined space refers to any place including any vessel tank, container, pit, bund, chamber, cellar or any other similar space which, by virtue of its enclosed nature, creates conditions that give rise to likelihood of an accident, harm or injury of such nature as to require emergency action due to 1. Presence or reasonable foreseeable presence of - Presence of explosive atmosphere - Harmful gas, fume or vapor - Free flowing solid or an increasing level of liquid - Excess of oxygen

- Excessively high temperature.

2. The lack of or reasonable foreseeable lack of oxygen(picture of confined space warning) KEY CHARACTERISTICS OF A CONFINED SPACE ARE 1. The space must be substantially enclosed 2. There must be a risk of at least one of the hazards listed above occurring within the space 3. The risk of serious injury from the hazard must be created by virtue of the enclosed nature of the space. 4. The potential injury must be serious and be such as to require emergency action to rescue the person involved. WHAT ARE THE HAZARDS ASSOCIATED WITH CONFINED SPACE The hazards associated confined spaces include:

 Toxic Atmosphere

 Oxygen Deficiency

 Oxygen Enrichment

 Flammable or Explosive Atmospheres

 Flowing Liquid or Free Flowing Solids

 Excessive Heat

WHAT ARE THE SAFETY REQUIREMENTS WITH REGARDS TO CONFINED SPACE ENTRY The safety, health and welfare at work (confined spaces) regulations 2001 cover all work in relation to confined spaces REGULATION 5 states that 1. A person shall not carry out work in confined space if it is reasonably practical that it could be avoided. 2. If the work must be carried out, hazard identification and risk assessment must be carried out prior to the work commencing.

3. A person shall not enter a confined space unless there is a system of work in place that has been planned, organized, performed and maintained so as to render that work safe and without risk to health. 4. Anyone entering a confined space must be provided with appropriate training, information and instruction appropriate to the particular characteristics of the proposed work activities. WHAT ARE THE LEGAL REQUIREMENTS IN RELATION TO EMERGENCY ARRANGEMENTS FOR CONFINED SPACES? REGULATION 6 of the confined space regulation 2001 states that: 1. A person shall not enter a confined space unless the suitable arrangements have been made which are appropriate to the confined space in question. 2. The emergency arrangements shall include: - All practical measures necessary to ensure the health and safety of those taking part in the rescue. - The provision of a suitable and reliable means of raising the alarm in the event of an emergency. - Having all necessary rescue equipment nearby in a well maintained, good condition. - The provision of information, instruction, and training to all involved in rescue procedures. - The provision of equipment and training for resuscitation procedures if there is foreseeable risk that they will be needed. WHAT SHOULD I LOOK FOR IN A CONFINED SPACE RISK ASSESSMENT 1. What could be inside the space that would pose a risk? - Contents - Oxygen deficiency - Previous contents - Oxygen enrichment - Residue - Structure and layout - Contamination

2. What will be created due to the work carried out in the space? - Sources of ignition - Flammable substances

3. What outside the space might pose a risk during the proposed work? - Inadequate isolation - Inadvertent operation of plant - Nearby work activities

EXEMPTIONS FROM THE SAFETY, HEALTH AND WELFARE (CONFINED SPACE) The regulations do not apply to any place below ground in a mine ( as defined by the Mines and Quarries Act 1965) or to any diving operations. WHAT ARE THE KEY ELEMENTS OF A SAFE SYSTEM OF WORK OF A CONFINED SPACE? 1. Competence, training, supervision and sustainability 2. Permit-to-work procedure 3. Gas purging and ventilation 4. Absence or safe handling of dangerous residues 5. Testing and monitoring of the atmosphere 6. Mechanical, electrical and process isolation. 7. Respiratory protective equipment 8. Safe use of work equipment 9. Communications 10. Access and Egress 11. Other personal protective equipment 12. Absence or safe handling of flammable or explosive atmosphere 13. Absence or safe handling of combustible materials. WHAT IS A PERMIT TO WORK PROCEDURE? A permit to work procedure is a means of achieving effective control of a system of work through formal written documentation known as permit to work form. 2.16 ELECTRICITY IN THE WORK PLACE Places of work generally have power nominally supplied at 230 volt (single phase) and 400 volt (3 phase) although some larger workplaces will receive electricity at a higher supply voltage. The information below relates to workplaces using 230 and 400 volt supplies. The main hazards with electricity are:

 contact with live parts causing shock and burns

 faults which could cause fires;

 Fire or explosion where electricity could be the source of ignition in a potentially flammable or explosive atmosphere, e.g. in a spray paint booth.

The risk of injury from electricity is strongly linked to where and how it is used and there is greater risk in wet and/or damp conditions. Basics of Contact with Electricity

It is the level of voltage the body is exposed to and the resistance to flow of electrical current offered by the body that determines the impact of exposure to electricity. The following factors determine the severity of the effect electric shock has on your body:

 The level of voltage

 The amount of body resistance you have to the current flow

 The path the current takes through your body

 The length of time the current flows through your body

If a worker has come into contact with electricity the worker may not be able to remove themselves from the electrical source. The human body is a good conductor of electricity. If you touch a person while they are in contact with the electrical source, the electricity will flow through your body causing electrical shock. Firstly attempt to turn off the source of the electricity (disconnect). If the electrical source cannot readily and safely be turned off, use a non- conducting object, such as a fiberglass object or a wooden pole, to remove the person from the electrical source. As an Employer it is YOUR responsibility to ensure: Extension cables and other flexible leads which are particularly prone to damage to plugs and sockets and to their connections are visually checked, maintained and where necessary replaced before using portable equipment. The ends of flexible cables should always have the outer sheath of the cable firmly clamped to stop the wires (particularly the earth) pulling out of the terminals

 Use the correct cable connectors or couplers to join lengths of cables together and do not allow taped joints.

 Electrical installations are installed and maintained by a competent person and checked regularly

 Socket Outlets are not overloaded by the use of adaptors

 Electrically powered equipment provided is suitable for use

 Fixed electrical equipment should have a clearly identified switch to cut off power in an emergency

 that portable equipment labelled as being double insulated has had the live and neutral connected properly to the plug by a competent person unless the plug is of a molded type Controlling the Risk Reduce the Voltage Often portable equipment is available that is powered from a 110 volt supply through a simple transformer and these are often center tapped to earth so that the maximum voltage between a

36 live conductor and earth (the most common cause of electric shocks from equipment) is limited to 55V. Battery operated tools such as drills, screwdrivers etc. can replace mains powered equipment

 Temporary and hand held lighting can be provided at 12, 25, 50 or 110 volts.

Ensure Fuses are correctly fitted

 The fuse protects the device from over current. It is designed to ‘blow’ and cut off the electricity when the current exceeds its rated capacity. It is important to ensure the correct fuse is used for the appliance. As a general guide 3 amp fuses are used in equipment up to 700 watts (W). For equipment with a rating greater than 700 watts (W) a 13-amp fuse will be required. Some equipment requires a 5 amp fuse e.g. some televisions and, other equipment like some printers require 10 amp fuses. Always read the manufacturer’s instructions.

Earthed Equipment Class 1 equipment relies for its safety upon being connected to earth via the plug. If any live parts come in to contact with the casing or earthed parts of the equipment the fuse will ‘blow’ and cut the supply. When testing Class 1 equipment the earth bond test checks there is a secure connection to earth. The insulation test checks there is no preexisting earth fault Class 2 double insulated equipment has the symbol double square symbol indicating the equipment is double insulated and therefore has no earth wire. Double insulation requires that the devices have both basic and supplementary insulation, each of which is sufficient to prevent electric shock. All internal electrically energized components are totally enclosed within an insulated body that prevents any contact with "live" parts. In the EU, double insulated appliances all are marked with a symbol of two squares, one inside the other. Provide One or More Residual Current Device (RCD) If equipment operating at 230 volts or higher is used, an RCD (residual current device) can provide additional safety. RCD’s are supplementary protection devices, which do not prevent an electrical shock, but are able to limit the duration of some shocks by enabling the rapid disconnection of the electricity supply, when an electrical shock takes place. RCD's are mandatory on all circuits supplying portable equipment and on certain other circuits where the hazard of electricity is exacerbated by the proximity of water. An RCD is a device which detects some, but not all, faults in the electrical system and rapidly switches off the supply. The best place for an RCD is built into the main switchboard or the socket-outlet, as this means that the

37 supply cables are permanently protected. If this is not possible then a plug incorporating a RCD, or a plug-in RCD adaptor can be used to provide additional safety.

 RCD's for protecting people have a rated tripping current (sensitivity) of not more than 30 milliamps (mA).

 an RCD is a valuable safety device, never bypass it;

 If the RCD trips, it is a sign there is a fault. Check the system before using it again;

 if the RCD trips frequently and no fault can be found in the system, consult the manufacturer of the RCD;

 The RCD has a test button to check that its mechanism is free and functioning and should be used regularly.

Chapter 3 – Challenges encountered by student. 3.1 MEMORIZING THE NOMENCLATURE AND CLASSIFICATION OF TOOLS It took me a significant amount of time to get used to the names and the classifications of the tools we used. I had trouble working at my boss’s pace because of this. Fortunately, over a short period, I completely understood the tools and can now tell which is which even just by feeling. 3.2 MISHANDLING OF LITTLE PARTS AND TOOLS Never have I been tasked with the responsibility to carefully track and keep very tiny materials even while working, and working fast at that. At the beginning I lost some tools, and I used to misplace parts of generators. Fortunately, over time I became better. 3.3 WORKING WITH CORRODED BOLTS AND NUTS. I had to get used to working with corroded bolts and nuts. Sometimes they can be very difficult to handle and can even dull the edges of your fastening tool. You may know what you need to do to get a broken down machine up and running but if you don’t know how to lose those nuts, your knowledge would be as effective as none. 3.4 LACK OF SPEED At the beginning, I was very slow because I was trying to understand the working of things, my boss had issues with me because of this. With time however, my speed increased very appreciably.

Chapter 4 – Observations & Contributions 4.1 OCCASIONAL UNAVAILABILITY OF SOME TOOLS DUE TO OVERSIGHT The company had very good, state of the art, high end facilities. But I noticed that, sometimes while working, some really basic tools, such as a spanner of a particular size that is unavailable, could delay the whole work for that day. Since it is a growing company, I decided to deploy empathy, believing that they would grow in their understanding to intentionally and carefully purchase and stock all tools and equipment that could be needed for any type of work. I made sure to stress the importance of these tools and equipment, as small as they may seem to them. Before I left, I can say that they became appreciably better in this aspect. 4.2 AVERAGE BUSINESS ACUMEN I also noticed that the engineers were very skillful, but they did not have the same level of command over the laws and knowledge of business. And this was a weak spot that showed itself true in some of our activities. I know this kind of occurrence is common among engineers so I also had to deploy empathy in this aspect and carefully push through my own experience in business to them. And I saw a satisfactory improvement in the way the business was handled.

Chapter 5 - Conclusion Working at GIL was a fascinating experience for me. It was fun because I got to move around and the work wasn’t monotonous or routine. I got both technical, leadership, and life experiences from the intelligent people I worked under. Spiritually, it was invaluable because for the first time in my life, I understood the meaning of Salvation when my boss carefully and illustratively explained it to me. It was meaningful and worthwhile work and I would be happy to relive the experience again if I have the luxury of time.

Chapter 6 - Challenges Observed as being faced by the SIWES Industry-based Firm 6.1 OCCASIONAL UNAVAILABILITY OF SOME TOOLS DUE TO OVERSIGHT It is very obvious by now, that one major difference between small companies and big companies is in the attention paid to details. Large companies are large because they care about little things, because they realize that those matters are the building blocks to a large company. One important small matter that is usually overlooked by average or mainstream companies is tools. They get the sophisticated tools and advanced machineries quite alright. But they usually pay less attention to the smaller seemingly mundane tools that are even more involved in everyday work. Ranging from the unavailability of a spanner of particular size, unavailability of a little oil funnel, a dull-end screwdriver, broken tools, etc. Failure to promptly purchase these little tools, or replace damaged or lost ones, usually lead these small companies to over improvise causing a great deal of inefficiency and ineffectiveness in work done. The company I worked for, had very good, state of the art, high end facilities. But I noticed that, sometimes while working, some really basic tools, such as a spanner of a particular size that is unavailable, could delay the whole work for a whole day. Since it is a growing company, I decided to deploy empathy, believing that they would grow in their understanding to intentionally and carefully purchase and stock all tools and equipment that could be needed for any type of work. I made sure to stress the importance of these tools and equipment, as small as they may seem to them. Before I left, I can say that they became appreciably better in this aspect.

6.2 AVERAGE BUSINESS ACUMEN In present time, there are many endeavors and exploits that humans now engage in that cuts across engineering, health, law, sports, entertainment etc. Since humans have needs, they have figured out ways to develop skills in areas that they are passionate about and sell their services, thereby creating business. So, with a good understanding of what was said above, we can conclude that business cuts across all fields of human endeavors. Whatever you are doing with an aim to sell your skills as services is a business. And the aim of business is to sell and make profit. What I have observed is that many freelance engineers are not equipped with business skills and this limits the returns on their business. They usually tend to be weak and emotional in things like bargaining, pricing, pitching, and customer relations in general. I observed this trait lightly during my stay of GIL, especially during the time I worked with the generator technician, when we frequently interacted with different kinds of clients. I also noticed that the engineers were very skillful, but they did not have the same level of command over the laws and knowledge of business. And this was a weak spot that showed itself true in some of our activities. I know this kind of occurrence is common among engineers so I also had to deploy empathy in this aspect and carefully push through my own experience in business to them. And I saw a satisfactory improvement in the way the business was handled.

Related Diagrams For a better reading experience of this report, all related diagrams were embedded in the body of the report. Hence, the reason for this section being blank. Kindly refer to body.