CHAPTER ONE

1.0 INTRODUCTION
SIWES was established by ITF in 1973 to solve the problem of lack of adequate
practical skills preparatory for employment in industries by Nigerian graduates
of tertiary institutions.
The Scheme exposes students to industry based skills necessary for a smooth
transition from the classroom to the world of work. It affords students of tertiary
institutions the opportunity of being familiarized and exposed to the needed
experience in handling machinery and equipment which are usually not
available in the educational institutions.
Participation in Industrial Training is a well-known educational strategy.
Classroom studies are integrated with learning through hands-on work
experiences in a field related to the students academic major and career goals.
Successful internships foster an experiential learning process that not only
promotes career preparation but provides opportunities for learners to develop
skills necessary to become leaders in their chosen professions.
One of the primary goals of the SIWES is to help students integrate leadership
development into the experiential learning process. Students are expected to
learn and develop basic non-profit leadership skills through a mentoring
relationship with innovative non-profit leaders.
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1.1 OBJECTIVES AND BENEFITS OF THE SCHEME

The following are some of the objectives of the students industrial work
experience scheme:
It provides students the opportunity to test their interest in a particular
career before permanent commitments are made.
The student will develop skills in the application of theory to practical
work situations.
SIWES will provide students the opportunity to test their aptitude for a
particular career before permanent commitments are made.
SIWES students will develop skills and techniques directly applicable to
their careers.
It aids students in adjusting from college to full-time employment.
It will provide students the opportunity to develop attitudes conducive to
effective interpersonal relationships.
It helps to increase a student's sense of responsibility.
It helps students to get prepared to enter into full-time employment in
their area of specialization upon graduation.
SIWES students will develop employment records/references that will
enhance employment opportunities
SIWES will provide students the opportunity to understand informal
organizational interrelationships.
SIWES Students will be able to outline at least five specific goals with
several staff members by comparing performance with job duties and
develop a draft plan with staff to accomplish performance needs,
supervision plan and rewards.

 SIWES Students will be able to develop a draft agency or project budget

and will be able to identify methods of obtaining revenue to support the
budget.
1.2 COMPANYS PROFILE
IYKEDEBOUR GLOBAL RESOURCES is located at G.R.A phase 2
Portharcort, Rivers State, Nigeria.
It is a registered multi-disciplinary company under Company and Allied Matters
Acts (CAMA 1990) with registration no. RC248647 in Nigeria. It is an
indigenous production company. It is well equipped and works are handled with
great technical know-how. With specialty in the areas of plastic waste
management equipment and others with a burning heart to move Nigeria
forward.
Our staff members are highly skilled and have years of experience and
certifications. But, their dedication to making sure your needs are met doesnt
come from that, it comes from within. And its embraced and appreciated by all
of our staff.
1.3 COMPANYS ORGANIZATIONAL STRUCTURE
A construction companys organizational structure refers to both the
arrangement of job roles and the reporting and operational relationships
between and within these roles.
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Fig 1.1 IYKEDEBOUR GLOBAL RESOURCES ORGANOGRAM

CHAPER TWO
2.0 EXPERIENCE GAINED DURING ATTACHMENT
2.1 SAFETY

Most of the departments in the IYKE DEBOUR RESORCES (IDR) rely on the
competency of the engineering department for the companys image depends on
them. Thus there is need to have a department or a section within the
organization that will see to the procurement, distribution, installation and
maintenance.
The best known safety device is a careful individual. A machine tool operated
intelligently with fore thought, will do all that it is intended to do. Carelessness,
negligence, thoughtlessness and over confidence on the part of the operator may
result in personal injury or damage to a costly machine.
Safety precaution guide lines for workers and personnel present on the
construction site;
The proper clothing is essential to safety. Wear clothes that are smart
and appropriate for the site work (the overall). Loose clothing is
dangerous for worker around the power tools and equipment.
Footwear must be safety boots or work boots that are thick-soled
shoes in order to protect the feet from falling objects or penetration by
metal chips and should have non-slip soles. Sandals or other types of
inappropriate footwear are hazardous on construction site.
Protective head gear (helmets or hard hats) must always be worn by
the workers on the construction site for the protection of the head
against falling object of any kind.

 Suspension belts are of crucial importance for site workers working at

very high levels.
Every worker must wear its hand gloves to protect them against hot
metals and chips.
The workers must be equipped with eyes shields to avoid damages
from the lightings from welding.
The workers must wear a transparent eye glass while using the filing
machine. Against chips running into his/her eyes.
The workers using the cutting machines must not pass their hands or
any part of their body the shear cutters blade. To avoid serious
injuries that might lead to loss of life.
A clean work place is a safe work place. This refers to the neatness
and good order of the construction site. Keep the construction site
clear of danger as you work remove unwanted scrap metals,
obstacles etc. They interfere with work and can constitute a hazard.
Malfunctioning machines can occur any time. It could happen during
the process of screw tightening or replacing the motor of the machine.
Irrespective of the type of breakdown, never try to work on it while
the machine is on and running.
Turn off the machine when wanting to hold the work piece.
Non-slip mats should be used in front of machines where necessary,
and machines should be sensibly placed to avoid overcrowding and
suitably anchored to vibration.
Maintain all the service records of machines and equipment. It will not
only save time but also help you to take care of repetitive break
downs.
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 All the tools and accessories must be kept back at their relevant
places. Placing them anywhere will lead to chaos and inefficient
working.
Smoking and drinking should be prohibited in the construction site.
The gangway through the workshop must be kept clear. Any grease or
oil spillage must be cleaned on a regular basis.
There should be no talking while operating the machining. You might
be distracted.
Immediately notify the supervisor of any broken or faulty equipment.
Keep clear of any person operating tools and machinery (bumping and
operator or get a tangled in the lead could cause serious injury to you
or the operator).
Long hairs should be tied while operating the machine.
Remove rings and loose jewellery before operating machinery. They
can be hazards.
Know what a knob works before hitting it.
These are some safety precautions to observe while working on a machine in
the workshop;

Keep machines and all equipment clean, and in good condition.

Before starting a machine ensure that you know how to stop it.
Switch off the machine immediately anything goes wrong.
Keep the machine and surrounding area tidy.
Check oil before first starting machines.
Switch off machine at mains at end of each day.
Check that chucks or cutters rotate in the correct direction before

commencing cutting operations.

Use the correct tool of cutter for the job.
Replace tools that are worn or damaged.
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 Keep tools and cutter in boxes or racks when not in use.

Report immediately to your instructor any mechanical or electrical
fault.
Ensure that all machine guards are in position, before starting the
machine.
Do not attempt to operate a machine until you know how to use it
correctly.
Do not remove any stops in an effort to obtain a greater cutting range,

or the machine may be seriously damaged.

Do not try and reverse the direction of a spindle while it is in motion.
Do not try to change a spindle speed while it is in motion.
Do not throw things.
Do not walk away and leave your machine running.
Do not direct impressed air at yourself or work mates, It is very
hazardous.

2.2 WORK EXPERIENCE

These are some sequence of activities in the engineering department which I
took part in;

Surface cleaning.
Cutting and machining.
Punching and drilling.
Straightening, bending and rolling.
Fastening (bolting, riveting and welding).
Finishing.

2.2.1 SURFACE CLEANING

Structural sections from the rolling mills may require surface cleaning to
remove mill scale prior to fabrication and painting. Hand preparation, such as
wire brushing, does not normally conform to the requirements of modern paint
or surface protection system. Blast cleaning is the accepted way of carrying out
surface preparation in a well-run fabrication shop. Abrasive particles are
projected on to the surface of the steel at high speed by either compressed air or
centrifugal impeller to remove rust and roughen the surface before applying the
coating. By using shot or slag grits, both of which have an angular profile,
surface oxides are removed and a rougher surface is obtained to provide an
adequate key for metal spraying or special paint.
Flame cleaning is another method of surface cleaning. In this method the
surface is cleaned using an oxy-acetylene torch which works on the principle of
differential thermal expansion between steel and mill scale. In another method
called the steel piece is immersed in a suitable acid and the scale and rust are
removed.

2.2.2 CUTTING AND MACHINING

Following surface preparation, cutting to length is always the first process to be
carried out, and this is done by any of the following methods.
Shearing and cropping
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Sections can be cut to length or width by cropping or shearing using hydraulic

shears. Heavy sections or long plates can be shaped and cut to length by
specialist plate shears. For smaller plates and sections, machines featuring a
range of shearing knives, which can accept the differing section shapes, are
available.
Flame cutting or burning
In this method, the steel is heated locally by a pressurised mixture of oxygen
and a combustible gas such as propane, which passes through a ring of small
holes in a cutting nozzle. The heat is focussed on to a very narrow band and the
steel melts at 15000 C when a jet of high-pressure oxygen is released through a
separate hole in the centre of the nozzle to blast away the molten metal in
globules. The desired cuts are obtained quickly by this process. However due to
a rapid thermal cycle of heating and cooling, residual stresses and distortion are
induced and hence structural sections that are fabricated using flame cutting are
treated specially in the design of structural steelwork.

Arc Plasma Cutting

In this method, the cutting energy is produced electrically by heating a gas in an
electric arc produced between a tungsten electrode and the work piece. This
ionises the gas, enabling it to conduct an electric current. The high-velocity
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plasma jet melts the metal of the work piece. The cut produced by plasma jet is
very clean and its quality can be improved by using a water injection arc plasma
torch. Plasma cutting can be used on thicknesses up to about 150 mm but the
process is very slow.
2.2.3 PUNCHING AND DRILLING
Most fabrication shops have a range of machines, which can form holes for
connections in structural steelwork. The traditional drilling machine is the radial
drill, a manually operated machine, which drills individual holes in structural
steelwork. But this method has become too slow for primary line production.
Therefore, larger fabricators have installed NC (Numerically Controlled)
tooling, which registers and drills in response to keyed in data. These can drill
many holes in flanges and webs of rolled steel sections simultaneously. It is also
possible to punch holes, and this is particularly useful where square holes are
specified such as anchor plates for foundation bolts. While this method is faster
compared to drilling, punching creates distortion and material strain hardening
around the holes, which increase with material thickness. Its use is currently
restricted to smaller thickness plates. In order to reduce the effect of strain
hardening and the consequent reduction in ductility of material around punched
holes, smaller size (2 mm to 4 mm lesser than final size) holes are punched and
subsequently reamed to the desired size.
2.2.4 STRAIGHTENING, BENDING AND ROLLING
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Rolled steel may get distorted after rolling due to cooling process. Further
during transportation and handling operations, materials may bend or may even
undergo distortion. This may also occur during punching operation. Therefore
before attempting further fabrication the material should be straightened. In
current practice, either rolls or gag presses are used to straighten structural
shapes.
Gag press is generally used for straightening beams, channels, angles, and
heavy bars. This machine has a horizontal plunger or ram that applies pressure
at points along the bend to bring it into alignment. Long plates, which are
cambered out of alignment longitudinally, are frequently straightened by rollers.
They are passed through a series of rollers that bend them back and forth with
progressively diminishing deformation.
Misalignments in structural shapes are sometimes corrected by spot or pattern
heating. When heat is applied to a small area of steel, the larger unheated
portion of the surrounding material prevents expansion. Upon cooling, the
subsequent shrinkage produces a shortening of the member, thus pulling it back
into alignment. This method is commonly employed to remove buckles in girder
webs between stiffeners and to straighten members. It is frequently used to
produce camber in rolled beams. A press brake is used to form angular bends in
wide sheets and plates to produce cold formed steel members.
2.2.5 FASTENING METHODS
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The strength of the entire structure depends upon the proper use of fastening
methods. There are three methods of fastening namely bolting, riveting and
welding. A few decades back, it was a common practice to assemble
components in the workshop using bolts or rivets. Nowadays welding is the
most common method of shop fabrication of steel structures. In addition to
being simple to fabricate, welded connection considerably reduce the size of the
joint and the additional fixtures and plates. However, there is still a demand for
structural members to be bolted arising from a requirement to avoid welding
because of the service conditions of the member under consideration. These
may be low temperature performance criteria, the need to avoid welding stresses
and distortion or the requirement for the component to be taken apart during
service e.g. bolts in crane rails or bolted crane rails. Welding is used extensively
for joining metals together and there is no doubt that it has been a most
significant factor in the phenomenal growth of many industries.
A welded joint is made by fusing (melting) the steel plates or sections along the
line of joint. The metal melted from each member of the joint unites in a pool
of molten metal, which bridges the interface. As the pool cools, molten metal at
the fusion boundary solidifies, forming a solid bond with the parent metal.
When solidification completes, there is a continuity of metal through the joint.
There are five welding process regularly employed namely:
Shielded Metal Arc Welding (SMAW)
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This is basically a semi-automated or fully automated welding procedure. The

type of welding electrode used would decide the weld properties. Since this
welding is carried out under controlled condition, the weld quality is normally
good.
Submerged-Arc welding (SAW)
This is fully mechanised process in which the welding head is moved along the
joint by a gantry, boom or tractor. The electrode is a bare wire, which is
advanced by a motor. Here again, since the welding is carried out in controlled
conditions, better quality welds are obtained.

Manual Metal-Arc welding (MMA)

This is the most widely used arc welding process and appears to be
advantageous for labour intensive Indian construction practices.

As it is

manually operated it requires considerable skill to produce good quality welds.

Hence in the case of MMA, stringent quality control and quality assurance
procedures are needed. In India, the Welding Research Institute, BHEL, Trichy,
Tamil Nadu, conducts periodical courses for welders and weld inspection
personnel. Welders who are employed in actual fabrication are in fact, graded
according to their training and skills acquired.
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 Metal-Active Gas welding (MAG)

This process is sometimes referred to as Metal-Inert Gas (MIG) welding. It is
also manually operated. A gas that does not react with molten steel shields the
arc and the weld pool. This protection ensures that a sound weld is produced
free from contamination-induced cracks and porosity.

Nevertheless, this

procedure also depends on the skills of the welder.

Stud welding
This is an arc welding process and is extensively used for fixing stud shear
connectors to beam in the composite construction. The equipment consists of
gun hand tool, D.C. power source, auxiliary contractor and controller. The stud
is mounted into the chuck of the hand tool and conical tip of the stud is held in
contact with the work piece by the pressure of a spring on the chuck. As soon
as the current is switched on, the stud is moved away automatically to establish
an arc. When a weld pool has been formed and the end of the stud is melted the
latter is automatically forced into the steel plate and the current is switched off.
The molten metal, which is expelled from the interface, is formed into a fillet by
a ceramic collar or ferrule, which is placed around the stud at the beginning of
the operation.
This process offers an accurate and fast method for attaching shear connectors,
with the minimum distortion. While it requires some skill to set up the weld

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parameters (voltage, current, arc time and force), the operation of equipment is
relatively straight forward.

2.2.6 FINISHING
Structural members whose ends must transmit loads by bearing against one
another are usually finished to a smooth even surface. Finishing is performed by
sawing, milling or other suitable means. Several types of sawing machines are
available, which produce very satisfactory finished cuts. One type of milling
machine employs a movable head fitted with one or more high-speed carbide
tipped rotary cutters. The head moves over a bed, which securely holds the work
piece in proper alignment during finishing operation.
Bridge specifications require that sheared edges of plates over a certain
thickness be edge planed. This is done to remove jagged flame cut edges and the
residual stresses at the edges. In this operation, the plate is clamped to the bed
of milling machine or a planer. The cutting head moves along the edge of the
plate, planning it to a neat and smooth finish.
The term finish or mill is used on detail drawings to describe any operation that
requires steel to be finished to a smooth even surface by milling, planning,
sawing or other machines.
2.3 EQUIPMENTS USED IN THE MANUFACTURING PROCESS
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These are some of the equipment used by the engineering department of IYKE
DEBOUR GLOBAL RESOURCES;

Hydraulic shear cutting machine

Hydraulic manual bending machine
Hydraulic punching machine
Welding machine and handle
Oxyacetylene gas cutter
Hand Filing machine
Grinding machine
Drilling machine
Electrodes (gauge 8, 10, 12 and low hydrogen)
Airless spray machine
Vice
Measuring tape
Spanners (different sizes)
Sand papers
Metal hammer

2.3.1 HYDRAULIC SHEAR CUTTING MACHINE:

Hydraulic shear are used in high volume metal fabrication operations that
require the ability to accurately and quickly cut and score sheets of metals. The
cutting mechanism is enclosed inside a large stand-alone unit that can be as
much as ten feet tall and sixteen feet long.
The metal to be cut is inserted into a hydraulic shear and held in place with
clamps in the machine so that it does not shift. The machine cutter blade is
pulled down by pressing the lowering button. A small blur may be formed by
the edge of the blade, which can be ground off. It cuts steel plate of 1mm

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diameter to 6mm diameter. Any plate that exceeds that diameter can cause
damages to the machine or may as well not be cut.
2.3.2 HYDRAULIC MANUAL BENDING DEVICE
Manual hydraulic bender is used in fabrication operations that require the ability
to accurately bend pipes. The pipe is inserted in the device and clamped
between two dies, the clamping block and the forming die. The pipe passes
through the hydraulic jack in the stand. The handle is moved up and down
which makes the jack press against the pipe, causing it to bend.
2.3.3 WELDING MACHINE AND HANDLE
The welding machine is used to join metals of same and different properties
with the help of welding handle and electrodes. Power is transferred from the
welding machine to the welding handle through a cable. The welding handle is
used to hold or clamp the electrode before welding can occur. Two metals are
joined at desire form, then welded.
2.3.4 OXYACETYLENE GAS CUTTER
The oxyacetylene gas cutter is used for cutting metal sheet, angle irons and is
used to melt a welded joint. Oxyacetylene gas cutter produces flame which
burns above 3200 to 3500c degree, highest among commonly used gaseous
fuels. In oxyacetylene cutting, a torch is used to heat metal to its kindling
temperature. A steam of oxygen is then trained on the metal, burning it into a
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metal oxide that flows out of the kerf as slag. Oxyacetylene cutting requires two
isolated supplies, acetylene and oxygen. The oxy acetylene has two cylinders
contained with fuel and oxygen. There is about 1700kpa pressure in the tank
when full.
2.3.5 HAND FILING/CUTTING MACHINE
The hand filing/cutting machine is a motor machine that Rotates at a very high
speed to be able to cut. The machine is uses abrasive stone for cutting and grind
operation. As cut is being made, the abrasive wears out and are replaced once
they are incapacitated. A grinding stone is fit to it at the rotor and tightened
when a grinding operation is to be performed. Either way, a cutting stone can be
placed when wanting to make a cut. The machine consists of two handles, the
switch and the abrasives.
2.3.6 DRILLING MACHINE
The drilling machine is used to create hole in a component or metal sheet. It is
usually motor-driven, fitted with an end cutting tool that is rotated with
sufficient power either to create a hole or to enlarge and existing hole in a solid
material. A drilling machine makes holes with removal of chips. It can be used
for other operations such as countersinking, reaming, tapping and boring.
Several types are used in metal working; vertical drilling machines, horizontal

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drilling machines, centre-drilling machines, gang drilling machines, multiplespindle drilling machines and special-purpose drilling machines.
2.3.7 VICE
A vice is a mechanical apparatus used to secure an object to allow work to be
performed on it. Vices have two parallel jaws, one fixed and the other movable
threaded in and out by a screw and lever. The work piece is inserted between the
two parallel jaws to good working position, the handle it turned clockwise to
tighten the jaw thereby enclosing the work piece between the jaws. Then
machining can be carried out.

Fig 1.2 Some Equipment used in manufacturing process

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CHAPTER THREE
3.0 RECOMMENDATION AND CONCLUSION
3.1 RECOMMENDATION
In as much as industrial training is worthy to be experienced, there are some
problems that go with it. I thereby recommend the following;
ITF and institutions should help and ensure proper placement of
students based on their field of study so as to ensure that our
graduates will be fully baked so as to fit into the labour market to
help improve the countrys economy.
ITF and institution based supervisors should see that the students
are visited regularly which will help them keep to attendance in their

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places of attachment and also focus more on the training so as to be

able to adopt a good working ethics.
Also the senior staff should give the junior ones (including the
student) more task to carry out which will help them learn more and
also develop the attitude of self-confidence.
Employment of more qualified operators to lessen the load of work/
activities on the operators.
Improving the maintenance department so as to be able to carry out
proper maintenance on materials, tools and equipment used to carry
out various jobs or activities.
The Government, ITF and the institutions should organize a reorientation programs for our industries (especially those private
owned establishments) and prospective employees in regards to
engaging IT students.
3.2 CONCLUSION
From the training, I have no doubt that the Students Industrial Work Experience
Scheme (SIWES) had achieved the objective for which it was established. Not
only had the training exposed me to so many plants/equipments, but also to the
fundamental working principles of these plants, which are the theories being
taught at school. Moreover, it exposed me to the working environment ethics
and office routines. It also helped me to know more about human relationship as

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it entails working as a team and managing of personnel and equipment. The

Industrial Training is the bridge between paper qualification and practicality,
and as such should always be encouraged. Consequently, every Engineering,
Technology and Science student should endeavour to embark on Industrial
Training at the relevant time to enhance his/her knowledge.
Notwithstanding the benefits of the Industrial Training scheme, the problems
being encountered by the students during the training can derail the wellintended scheme and make it to lose its vitality and usefulness if most of these
serious problems were not appropriately addressed. It is my supposition that the
authorities concerned will look into these problems and proffer solutions to
remedy the situation. Finally, i appreciate the contributions and effort of those
who are involved in the implementation of this program, and the opportunity
given to me to develop myself.

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