NAME: NWEKE CHRISTIAN SOMKENECHUKWU

MAT. NO. : 13CF015151

PROGRAM: CHEMICAL ENGINEERING
COURSE: GEC 229
COURSE TITLE: STUDENTS WORK EXPERIENCE PROGRAM
(S.W.E.P)
TITLE: REPORT ON ALL THE WORKSHOPS- ACTIVITIES
PERFORMED

GEC 229 entails 4 Engineering Buildings

1. MECHANICAL ENGINEERING BUILDING

2. CIVIL ENGINEERING BUILDING
3. ELECTRICAL/ ELECTRONICS ENGINEERING BUILDING
4. CHEMICAL/ PETROLEUM EGINEERING BUILDING

MECHANICAL ENGINEERING BUILDING

The Objective of the visit to mechanical engineering department was for students to have a brief
knowledge of the different workshop sections and also know the functions or operation
performed in the various sections and also the safety precautions to observe for a successful
workshop experience.

Mechanical Engineering has 4 workshops which are

Foundry workshop
Machine workshop
Metal Fabrication and Welding unit
Automobile workshop

1. FOUNDRY WORKSHOP

Foundry is a place where metal and glass are casted. It is involves the process of producing
metal objects called CASTING by pouring molten metal into a hollow mould usually made of
sand.

Departments in Foundry: Design room, Pattern shop/ room, Sand preparation, Moulding
section, Furnace, Scrap room and Machine shop
DESIGN ROOM: A draughtsman talks the measurements, thickness, diameter and specifications
of the material to be casted.

Instruments include: Mathset, T-Square, Paper, T.D Board.

PATTERN SHOP

The pattern maker makes the pattern of the material according to the drawing given to him by
the draughtsman. Wood is mostly used to make the pattern, P.OP (Plaster Of Paris), Resin, Metal
and Wax can also be used to make the pattern.

In case the product has a hollow like a cup. A pattern made of sand called CORE is placed in the
mould to form the hollow.

Instruments include: Saw, Sandpapers, Files, Nails and Hammer

SAND PREPARATION

The moulding sand consists of

Silica sand It can withstand high temperature of the molten metal and it is very loose
Bentonite: It acts a binder of the silica sand. Starch can also be used as a binder.
Coal dust: It helps the moulding sand to collapse well
Water: Acts as the substance to mix the other various components

Instruments: Head pan, Wheelbarrow

MOULDING SECTION

This is where we prepare the hollow mould. We ram to compile the sand and make it dry. As the
cope and drag (a set if buckets on top of each other with open ends) is joined, parting sand is
placed in between in order to prevent the cope and drag from sticking together. Runner pipe is
used to create the passage for the molten metal to enter the mould or a drilling machine is used
to make a hole to the impression.

Instruments: Mould boxes (Cope and drag), Shovel, Ramming Stick

FURNACE

It is an enclosed apparatus where heat is produced or generated.

Types of furnace

Crucible type furnace- Used in Covenant University. It has 2 types which are Tilting
furnace which can be tilted for molten metal to flow and the Crucible normal furnace
that cannot be tilted

Rotary furnace
 Cupola furnace

Instruments: Ladle

SCRAP ROOM

Types of Scrap

Cast Iron (1850 oC), Zinc (400 oC), Aluminium (650 oC), Copper (900 oC), Lead (300 oC)

2. MACHINE SHOP

A machine shop is a room, building, or company where machining is done. A machine shop
generally consists of one or more workrooms containing major machine tools, some other
equipment and skilled labour to manufacture and/or repair parts. Although a machine shop can
be a stand-alone operation, many businesses maintain internal machine shops which support
specialized needs of the business.

A machine shop can produce parts of different materials, such as metal, plastics, glass, or wood.
Machining in an engineering workshop could take any form of metal removal processes that
may include:

Cutting off, Drilling, Turning, Planing, Milling, Surface Grinding

CUTTING OFF

This is the first step in any given machining operation in an engineering workshop. This is
because every machining operation will usually begin with a rough cut of a blank, slug, or other
work piece to dimensions normally somewhat larger than finish sizes to allow for stock
removal.

Machines for common cutting off by sawing discussed were categorized into three, in
accordance to how they move their saw-teeth past the material being cut, as:

Circular blade saws the saw-teeth moves along the perimeter of a flat, circular blade e.g.
circular saw machines, radial cold saw, rotary saw, miter saw concrete saw, abrasive saw;

Reciprocating blade saws the blade reciprocates up and down or forward and backward e.g.
powered hacksaw.

DRILLING

Drilling is a cutting process that uses a drill bit to cut or enlarge a hole of circular cross-section
in solid materials. The drill bit is a rotary cutting tool, often multipoint. The bit is pressed
against the workpiece and rotated at rates from hundreds to thousands of revolutions per
minute. This forces the cutting edge against the workpiece, cutting off chips (swarf) from the
hole as it is drilled. Drilled holes are characterized by their sharp edge on the entrance side and
the presence of burrs on the exit side (unless they have been removed). Also, the inside of the
hole usually has helical feed marks.
MILLING
Milling is the machining process of using rotary cutters to remove material from a work piece
advancing (or feeding) in a direction at an angle with the axis of the tool. It covers a wide variety
of different operations and machines, on scales from small individual parts to large, heavy-duty
gang milling operations. It is one of the most commonly used processes in industry and machine
shops today for machining parts to precise sizes and shapes.

TOOLS USED IN THE MACHINE SHOP

There are two types of tools which are:

1. Machine: Gigantic and require electricity

2. Hand (Motor) :Practically little and do not need electricity

Activities carried out on the bench are called Bench Work and Fittings. Activities such as:

1. Marking out devices: To produce any component, you must mark out the dimensions of
the component.
Scriber: Also known as Engineering Pencil is used to mark out the dimensions
Steel rule: Used for measuring straight lines
Try square: Used with scriber to get a perfect 90o angle on the component
Height and depth gauge: Both are calibrated and used for measurement. It can
also be used to pin-point a straight line on the material.
Measurement tape: For linear measurement

2. Holding Device
Clamps: G-Clamp, F-Clamp, Vice

3. Cutting Tools:
Snip Chisel: To cut keyway, grooves and slots depending on your degree of
accuracy.
Hacksaw: Used for cutting mild steel rods. Do not use a new blade on an old cut,
start the other edge to avoid breakage.

4. Filing Tools:
File: Used for finishing in different shapes. It files unwanted chips. File types include
Half-round, Flat, 3-square, Round, Triangle files.
Sandpaper: Used also finishing

5. Thread Cutting tools:

Lathe machine: Lathe machine can be used for both internal and external thread
cutting
Tap holder/ Wrench with tap: It is made of H.S.S.(High Speed Steel), it is use for
internal threading

6. Striking tools:
Hammer- 1. Claw hammer 2. Ball pen Hammer-Used for a harder blow or force 3.
Straight pen hammer 4. Sledge hammer
Mallet: Used to give a gentle blow (made of rubber or Teflon)
 7. Scraping tools:
Scraper: Used to scrape a flat surface

8. Driving/ Bolting tools

Spanner : Includes Flat, Tubular, Ring spanner
Screwdriver: Includes star and flat screwdrivers.

3. METAL FABRICATION AND WELDING UNIT

What is Welding?

Welding is often done by melting the work pieces and adding a filler material to form a pool of
molten material (the weld pool) that cools to become a strong joint, with pressure sometimes
used in conjunction with heat, or by itself, to produce the weld. This is in contrast with soldering
and brazing, which involve melting a lower-melting-point material between the work pieces to
form a bond between them, without melting the work pieces. Welders can be found in lots of
places and in lots of companies these include the making of aeroplanes assembling cars and
other vehicles constructing buildings and bridges working on oil rigs in the middle of the
ocean and under the sea.

TYPES OF WELDING

Some of the best known welding methods include:

Shielded metal arc welding (SMAW) - also known as "stick welding", uses an electrode that has
flux, the protectant for the puddle, around it. The electrode holder holds the electrode as it
slowly melts away. Slag protects the weld puddle from the outside world.

Gas Tungsten-Arc Welding- Gas Tungsten-Arc Welding is considered to be one of the most
difficult and time consuming of welding processes used today (along with Plasma Arc Welding).
This is because it requires a great amount of focus and skill due to the small area of space
between the arc of the flame and the material being welded. Usually, small strips of metal that
do not contain much iron are welded with this process.

ARC WELDING

Arc welding is one of several fusion processes for joining metals. By applying intense heat, metal
at the joint between two parts is melted and caused to intermix - directly, or more commonly,
with an intermediate molten filler metal. Upon cooling and solidification, a metallurgical bond is
created. Since the joining is an intermixture of metals, the final weldment potentially has the
same strength properties as the metal of the parts. This is in sharp contrast to non-fusion
processes of joining (i.e. soldering, brazing etc.) in which the mechanical and physical properties
of the base materials cannot be duplicated at the joint.

MATERIALS/ TOOLS

Arc Machine, Leather Gloves, Electrode, 2 mild steel rods 150mm, Hack Saw, Vice, Safety
Goggles, Laboratory coat/ Overall, Bucket of Water.
 4. AUTOMOBILE WORKSHOP

The economic life of a car is 8 years. An automobile consists of 13, 000 parts and 1,500
synchronized parts.

Steps on how to put on a car

Use the key to switch on the car, this acts to close the circuit.
Current will flow through the battery to the ignition coil which helps to magnify the
voltage to 30, 000V.
The current then goes to the distributor and links the spark plug which will ignite the
compressed petrol and air
Alternator takes over as soon as the car starts, it helps to charge back the battery. To
test if the alternator is faulty, start the car and remove one of the terminals of the
battery, if the car stops the alternator is faulty.
The headlamp is connected directly to the battery. The horn also works anytime
because it is connected to the battery.

Mechanism of a car is divided into

1. Engine, 2.Electrics, 3.Steering, 4.Suspension,

5. Wheel, Tyre 6. Transmission, 7.Bodywork 8.Brakes

The elements responsible for the respiration of fuel and air is carburettor or injector. We feed
cars air, water, engine oil, fuel. Anti-freeze is used in the water of the radiator to prevent it from
freezing and under-heating.

Excretion of an automobile: Exhaust pipe/ Silencer.

A car works on either a 2-stroke engine cycle or 4-stroke engine cycle

3 major parts of an engine

Cylinder head
Engine block
Sump.

T.D.C (Top Dead Centre) and B.D.C (Bottom Dead Centre)-As crankshaft rotates and moves
the piston upward and downward, T.D.C is the maximum limit for the piston moving
upward while B.D.C is the maximum movement for the piston downward.

CIVIL ENGINEERING BUILDING

CONCRETE WORKSHOP

Concrete is a composite material composed mainly of water, aggregate, and cement. Often,
additives and reinforcements are included in the mixture to achieve the desired physical
properties of the finished material. When these ingredients are mixed together, they form a fluid
mass that is easily molded into shape. Over time, the cement forms a hard matrix which binds
the rest of the ingredients together into a durable stone-like material with many uses.
CONCRETE MIXING RATIOS

When making concrete it's important to use the correct concrete mixing ratios to produce a
strong, durable concrete mix.

To make concrete there are four basic materials you need: portland cement, sand, aggregate
(stone), and water. The ratio of aggregate to sand to cement is an important factor in
determining the compressive strength of the concrete mixture.

A concrete mixture ratio of 1 part cement, 3 parts sand, and 3 parts aggregate will produce a
concrete mix of approximately 3000 psi.

Mixing water with the cement, sand, and stone will form a paste that will bind the materials
together until the mix hardens. The strength properties of the concrete are inversely
proportional to the water/cement ratio.

Basically this means the more water you use to mix the concrete (very fluid) the weaker the
concrete mix. The less water you use to mix the concrete (somewhat dry but workable) the
stronger the concrete mix.

Accurate concrete mixing ratios can be achieved by measuring the dry materials using buckets
or some other kind of measuring device. By measuring the mixing ratios you will have a
consistent concrete mix throughout your entire project.

HIGHWAY AND TRANSPORTATION

Highway engineering is an engineering discipline branching from civil engineering that involves
the planning, design, construction, operation, and maintenance of roads, bridges, and tunnels to
ensure safe and effective transportation of people and goods. Highway engineers must take into
account future traffic flows, design of highway intersections/interchanges, geometric alignment
and design, highway pavement materials and design, structural design of pavement thickness,
and pavement maintenance.

EQUIPMENTS USED IN HIGHWAY AND TRANSPORTATION

1. Compression machine: Used to analyze the elastic rate, bearing rate and strength of the
material and the products. Also used to evaluate the product break-down test and the
quality of the assembly on the process. They are used to determine the strength of
concrete that has been cast on the site

2. CBR machine: They are used for the acquisition, recording and presentation of soil test
data. They are used to calculate the bearing capacity of the soil. The bearing capacity is
the capacity of soil to support the loads applied to the ground.

GEODETICS

Surveying or land surveying is the technique, profession, and science of accurately determining
the terrestrial or three-dimensional position of points and the distances and angles between
them, commonly practiced by surveyors, and members of various engineering professions.
Geodetics is the science and art of making all essential measurements to determine the relative
position of points or physical and cultural details above, on, or beneath the surface of the Earth,
and to depict them in a usable form, or to establish the position of points or details.

Tools and equipment used in Geodetics Laboratory

1. Theodolite

A Theodolite is an instrument for measuring both horizontal and vertical angles, as used in
triangulation networks, and geo-location work. It is a tool used in the land surveying and
engineering industry, but theodolites have been adapted for other specialized purposes as well.
Other specialized purposes make Theodolites ideal for shop and factory floor layout of tools and
fixtures. They also work well for layout for the construction of concrete slabs, swimming pools,
golf courses, landscaping, and road design

2. Ranging Poles

Ranging rod is a surveying instrument used for marking the position of stations and for
sightings of those stations as well as for ranging the straight lines. Initially these were made of
light, thin and straight bamboo or of well-seasoned wood such as teak, pine or deodar and were
shod with iron at the bottom and surmounted with a flag about 25 cm square in size, but
nowadays these are made of metallic materials only

3. Surveyors Tripod

A surveyor's tripod is a device used to support any one of a number of surveying instruments,
such as theodolites, total stations, levels or transits. Many modern tripods are constructed of
aluminum, though wood is still used for legs. The feet are either aluminum tipped with a steel
point or steel. The mounting screw is often brass or brass and plastic. The mounting screw is
hollow to allow the optical plumb to be viewed through the screw

HYDRAULIC ENGINEERING

Hydraulic engineering is also another sub-discipline of civil engineering concerned with the
flow and conveyance of fluids, principally water and sewage. One feature of these systems is the
extensive use of gravity as the motive force to cause the movement of the fluids. This area of
civil engineering is intimately related to the design of bridges, dams, channels, canals, and
levees, and to both sanitary and environmental engineering.

The hydraulic engineer is concerned with the transport of sediment by the river, the interaction
of the water with its alluvial boundary, and the occurrence of scour and deposition. The
hydraulic engineer actually develops conceptual designs for the various features which interact
with water such as spillways and outlet works for dams, culverts for highways, canals and
related structures for irrigation projects, and cooling-water facilities for thermal power plants.

GEOTECHNICAL LAB

Geotechnical Engineering is a branch of civil engineering concerned with the engineering

behaviour of earth materials. It uses principles of soil mechanics, rock mechanics and
engineering geology to investigate subsurface conditions and materials, determine the relevant
physical, mechanical and chemical properties of the materials, evaluate stability of natural
slopes and man-made soil deposits, access risks posed by site conditions, design earthworks
and structure foundations and monitor site conditions, earthwork and foundation construction.
A typical geotechnical engineering project is said to begins with a review of project needs to
define the required material properties. Then follows a site investigation of soil, rock, and fault
distribution and bedrock properties on and below an area of interest to determine their
engineering properties. A geotechnical engineer determines and designs the type of
foundations, earthworks and pavement subgrades required for the intended man-made
structures to be built.

ELECTRICAL AND INFORMATION ENGINEERING

BUILDING
In this department we learnt how computers work, the role of the microprocessors which scan
the circuits checking for changes in current due to pressing and releasing a key. We also learnt
about various parts of the computer like;

1. The keyboard: this is used through the help of an inbuilt microprocessor which
generates a scan code to pass data into the computer. Every key has 2 scan codes one for
when depressed and another for when it is released. BIOS converts scan code to asking
code.
2. The mouse: this is a mechanical device with a roller/ball underneath that moves in a
direction that is mimicked by a cursor on the screen of the computer.
3. The CPU: this is the central station of the computer, this is where all data conversion
processes take place. It consist of a number of parts which aid in data collection and
information creation. Example of such parts are;
DVD drive: this uses a laser system to read data off DVDs.
Floppy Disk drive: when a floppy disk is inserted into this drive a motor beneath the
disk causes the disk to spin, this drive is use to read information off floppy.
Floppy Disk drive: when a floppy disk is inserted into this drive a motor beneath the
disk causes the disk to spin, this drive is use to read information off floppy disks.
Hard disk: this is where most of the data is stored in the computer. It can be called
the memory of the computer.

We also learnt about electrical safety such as the different classes of fires which are class A to
class C.

We also learnt about telecommunications, how the audio and visual data are produced in the
studio in various rooms and then sent at an extremely high frequency (EHF) to the satellite
which converts it to super high frequency (SHF) which is broadcasted to the earth and is picked
up by satellite dishes. A device called the low noise block (LNB). This device acts as a converter
and converts the SHF to intermediate frequency (IF). This is then transferred to the decoder and
available for view.

We also learnt about the various electrical installation types which are;

Surface wiring system: this is the cheapest form of wiring as it is not covered but
runs openly on the wall only held in place by clips. It is the most economical but is
prone to electric shock as the wires are exposed to the elements.
Trunking wiring system: this is almost like the surface wiring only that the wires are
passed through rectangular tubes which are clipped or nailed to the wall. This form
 of wiring protects the wires from the elements but is relatively expensive compared
to the surface wiring.
Conduit wiring system: this is the safest form of wiring as the wires are passed
through the wall with the aid of conduit pipes. This is the most expensive but also
the most advisable as it provides neat and safe work.
We also learnt the various color codes for wires: live-red or brown, neutral-blue or black, earth-
green or yellow or both. We were also taught the criteria for cable selection which are;

1. Current magnitude.
2. Ambient temperature.
3. Length of run.
4. Class of protection.

CHEMICAL/ PETROLEUM ENGINEERING DEPARTMENT

In this department, we learnt about paints which are surface coatings used for protection and
decoration and the various types of paints we have;

1. Oil based paint: gloss paint.

2. Water based paint: emulsion and textured.
We also learnt about the various components in paint which are;

1. Binder (resin): this is a liquid substance found in trees of thick bark. It is used to bind
the pigment particles together, may be used without pigment to make clear dry (varnish
film) and it gives the film some extra properties.
2. Pigment: this is what gives color to the paint, opacity, reinforces the binder, sanding
properties etc.
3. Solvent: this is a general term used to describe non-film forming liquids used in paints.
4. Additive: these are introduced into the paint to give it added properties like defoamers,
fungicides etc.

We also learnt about various paint defects and their causes, here are a number of these defects;

Shriveling
Foaming
Mud cracking
Lifting/Working up
Rainspotting/Blooming
Brush disturbance or Flocculation
Flaking
Cissing, and
Runs/Sags.

We also learnt how to make emulsion paint, here are the components and their concentrations;

1. Water-950ml
2. Pigment (yellow oxide)-2g
3. TiO2-90g
 4. CaCO3-750g
5. Anticide-15ml
6. Genepour-10ml
7. Formalin-7.5ml
8. Defoamer-10ml
9. Acrylic (binder)-210g
10. Nitrosol (thickener)-10g
11. MPG(mono-propyl-glycol)-7.5ml
For textured paint add marble dust as a component.

PETROLEUM ENGINEERING DEPARTMENT

In this department we learnt how to produce hair cream and balm.

For the production of hair cream the composition is;

1. Petroleum jelly-50g
2. Paraffin oil-50ml
3. Lanolin-50g
4. Fragrance-10ml
5. Pigment-a drop
6. Additives-2g
And for balm is;

1. Paraffin wax
2. Paraffin oil
3. Petroleum jelly
4. Menthol
5. Camphor
6. Eucalyptus
7. Peppermint oil