OFFICIAL SWEP REPORT

OFFICIAL SWEP REPORT. Nsikak Udombana 13CM015578 1301651 Mechanical Engineering GEC 229 I was a member of GROUP D during the SWEP program. The activities for the SWEP program started proper on 27th of May, 2015. My group started from the Civil engineering department.

CIVIL ENGINEERING. The activities of civil engineers are concerned with human satisfaction. It is a professional engineering discipline that deals with the design, construction, and maintenance of the physical and naturally built environment, including works like roads, bridges, canals, dams, and buildings Branches of civil engineering  Highway and transportation.  Geodetics.  Structural material.  Environmental.  Geotechnical.  Hydrology and hydrostatics. Highway and Transportation Transportation engineering is concerned with moving people and goods efficiently, safely, and in a manner conducive to a vibrant community. This involves specifying,

designing, constructing, and maintaining transportation infrastructure which includes streets, canals, highways, rail systems, airports, ports, and mass transit. It includes areas such as transportation design, transportation planning, traffic engineering, some aspects of urban engineering, queuing theory, pavement engineering, Intelligent Transportation System (ITS), and infrastructure management. Geodetic Engineering Surveying is the process by which a surveyor measures certain dimensions that generally occur on the surface of the Earth. Surveying equipment, such as levels and theodolites, are used for accurate measurement of angular deviation, horizontal, vertical and slope distances. With computerisation, electronic distance measurement (EDM), total stations, GPS surveying and laser scanning have supplemented (and to a large extent supplanted) the traditional optical instruments. This information is crucial to convert the data into a graphical representation of the Earth's surface, in the form of a map. This information is then used by civil engineers, contractors and even realtors to design from, build on, and trade, respectively. Elements of a building or structure must be correctly sized and positioned in relation to each other and to site boundaries and adjacent structures. Although surveying is a distinct profession with separate qualifications and licensing arrangements, civil engineers are trained in the basics of surveying and mapping, as well as geographic information systems. Surveyors may also lay out the routes of railways, tramway tracks, highways, roads, pipelines and streets as well as position other infrastructures, such as harbours, before construction Structural Material Structural engineering is concerned with the structural design and structural analysis of buildings, bridges, towers, flyovers (overpasses), tunnels, off shore structures like oil and gas fields in the sea, aero structure and other structures. This involves identifying the loads which act upon a structure and the forces and stresses which arise within that structure due to those loads, and then designing the structure to successfully support and resist those loads. The loads can be self-weight of the structures, other dead loads, live loads, moving (wheel) load, wind load, earthquake load, load from temperature change etc. The structural engineer must design structures to be safe for their users and to successfully fulfil this function; they are designed (to be serviceable). Due to the nature of some loading conditions, sub-disciplines within structural engineering have emerged, including wind engineering and earthquake engineering. Design considerations will include strength, stiffness, and stability of the structure when subjected to loads which may be static, such as furniture or self-weight, or dynamic, such as wind, seismic, crowd or vehicle loads, or transitory, such as temporary construction

loads or impact. Other considerations include cost, constructability, safety, aesthetics and sustainability. Environmental Engineering Environmental engineering is the contemporary term for sanitary engineering, though sanitary engineering traditionally had not included much of the hazardous waste management and environmental remediation work covered by environmental engineering. Public health engineering and environmental health engineering are other terms being used. Environmental engineering deals with treatment of chemical, biological, or thermal wastes, purification of water and air, and remediation of contaminated sites after waste disposal or accidental contamination. Among the topics covered by environmental engineering are pollutant transport, water purification, waste water treatment, air pollution, solid waste treatment, and hazardous waste management. Environmental engineers administer pollution reduction, green engineering, and industrial ecology. Environmental engineers also compile information on environmental consequences of proposed actions. Geotechnical Engineering Geotechnical engineering studies rock and soil, supporting civil engineering systems. Knowledge from the field of geology, mechanics, materials science, and hydraulics is applied to safely and economically design foundations, retaining walls, and other structures. Environmental efforts to protect groundwater and safely maintain landfills have spawned a new area of research called geo-environmental engineering. Identification of soil properties presents challenges to geotechnical engineers. Boundary conditions are often well defined in other branches of civil engineering, but unlike steel or concrete, the material properties and behaviour of soil are difficult to predict due to its variability and limitation on investigation. Furthermore, soil exhibits nonlinear (stressdependent) strength, stiffness, and dilatancy (volume change associated with application of shear stress), making studying soil mechanics all the more difficult. Hydrology and hydrostatics Water resources engineering is concerned with the collection and management of water (as a natural resource). As a discipline it therefore combines geology, hydrology, meteorology, conservation, environmental science, and resource management. This area of civil engineering relates to the prediction and management of both the quality and the quantity of water in both underground (aquifers) and above ground (lakes, rivers, and streams) resources. Water resource engineers analyse and model very small to very large

areas of the earth to predict the amount and content of water as it flows into, or out of a facility. Although the actual design of the facility may be left to other engineers. There are different aspects of work in civil engineering 1 wood work 2 concrete work 3 block work 4 plumbing work Wood work Objects made of or work done in wood, especially wooden interior fittings in a house, as mouldings, doors, staircases, or windowsills. Woods are typically sorted into three basic types: hardwoods typified by tight grain and derived from broadleaf trees, softwoods from coniferous trees, and man-made materials such as plywood

Concrete work Concrete is a composite material composed of water, coarse granular material (the fine and coarse aggregate or filler) embedded in a hard matrix of material (the cement or binder) that fills the space among the aggregate particles and glues them together. Concrete is usually mixed in definite proportion examples are below in order of decreasing strength. It is in the proportion of cement sand gravel 1:1:3 1:1.5:3 1:2:4 1:3:6 1:4:8 Gypsum can be added to make the cement harder. 2 head pans of cement equal to 1 bag of cement poor work cause buildings to collapse Block work Block is made of mortar (fine aggregate, cement, and water in definite proportions). There are two types of blocks

1 6 inches block which are 150mm 2 9 inches block which are 225mm Mixture ratio in cement ratio aggregate in other of decreasing strength 1:3 1:4 1:6 1:8 Siderite is used to produce block while mortar is used to join block Plumbing work Plumbing is the system of pipes, drains fittings, valves, valve assemblies, and devices installed in a building for the distribution of water for drinking, heating and washing, and the removal of waterborne wastes, and the skilled trade of working with pipes, tubing and plumbing fixtures in such systems Interlocking stones Cement concrete tiles and paving blocks are precast solid products made out of cement concrete. The product is made in various sizes and shapes viz. rectangular, square and round blocks of different dimensions with designs for interlocking of adjacent tiles blocks. The raw materials required for manufacture of the product are Portland cement and aggregates which are available locally in every part of the country.

Equipment used in the production of interlocking stones 1 shovel 2 hand trowel 3 head pan 4 gauge box 5 tapping rod 6 moulding plastic 7 Compressive strength machines 8 iron mould machine

9 wheel barrow Interlocking stone is a precast concrete the 3 major ingredients for producing it are cement, fine aggregate and water. Interlocking stones is concrete which is cast of site. It is also known as paving stone and it is used for external landscaping Advantages of interlocking stones 1 They do not flake or expand, they are flexible and permanent. 2 They are easy to clean and easy to replace. 3 They provide good finishing in external works. 4 They allow water pass through them easily. Processes involved in interlocking making Process of Manufacturing Cement concrete is a mixture of Portland cement, aggregates (sand and stone chips) and water. Aggregates passing through 4.7 mm on sieve are known as fine aggregates and the aggregates retained on this sieve are coarse aggregates. The process of manufacturing cement concrete paving blocks involves the following steps: a) Proportioning b) Mixing c) Compacting d) Curing e) Drying A concrete mix of 1:2:4 (cement: sand: stone chips) by volume may be used for cement concrete paving blocks with water to cement ratio of 0.62. The concrete mix should not be richer than1:6 by volume of cement to combined aggregates before mixing. Fineness modules of combined aggregates should be in the range of 3.6 to 4.0. All the raw materials are placed in a concrete mixer and the mixer is rotated for 15 minutes. The prepared mix is discharged from the mixer and consumed in the next 30 minutes. Vibrating table may be used to compact the concrete mix in the moulds of desired sizes and shapes. After compacting, the blocks are remoulded and kept for 24 hours in a shelter away from direct sun and winds. The blocks thus hardened are cured with water to permit complete moisturisation for 14 to 21 days. Water in the curing tanks is changed every 3 to 4 days. After curing, the blocks are dried in natural atmosphere and sent for

use. The concrete paving blocks gain good strength during the first 3 days of curing and maximum gains in strengths are secured in the first 10 to 15 days of curing. After curing, blocks are allowed to dry in shade so that the initial shrinkage of the blocks is completed before they are used in the work. A drying period of 7 to 15 days would normally complete the drying shrinkage after which they can be used. The concrete tiles are similarly produced with the help of semi-dry pressing of the mixture and allowed to set for 24-36 hours. It is cured in the tanks for 15 days. If need be water can also be sprinkled to gain maximum physical strength in 15-21 days Building crew

Client A person or organization using the services of a lawyer or other professional person or company.

Land surveyor This is the first person you contact. He gets the land and issues a survey plan for you. Then he will give the governor who will sign and give the C of O.

Architect This is a person who plans, designs, and oversees the construction of buildings. He makes the plan on paper and gives it to the structural engineer. To practice architecture means to provide services in connection with the design and construction of buildings and the space within the site surrounding the buildings that have as their principal purpose human occupancy or use.

Structural engineer This is a person whose role is to inspect, provide and overseer the construction of the required structures needed.

Urban and regional planner Urban and regional planners develop plans and programs for the use of land. Their plans help create communities, accommodate population growth, and revitalize physical facilities in towns, cities, counties, and metropolitan areas. They tell you where your building should face.

Quantity surveyor It is a professional working within the construction industry concerned with construction costs and contracts. Services provided by a Quantity Surveyor may include:

     

Cost planning and commercial management during the entire life cycle of the project from inception to completion Value engineering Risk Management and calculation Procurement advice and assistance during the tendering procedures Commercial Management and Contract Administration Assistance in dispute resolution

Builder There are two types of builders 1 resident builder 2 visiting builder They manage the production process of the building

Services engineers This is the engineering of the internal environment and environmental impact of a building. It essentially brings buildings and structures to life. They mainly involve electrical and mechanical engineers.

Estate manager They are mainly concern with how close the building is to the road Stages involved in raising a structure 1 preparatory stage 2 construction stage 3 distribution stage 4 service stage

ELECTRICAL AND ELECTRONICS ENGINEERING. Electrical danger cannot be assumed easy. The danger is difficult to trace since the flow of current cannot be seen. If the current flow in the wrong direction, the current can defect human body, cause a shock, paralyzed, fire, explosion, death and others. This accident can be prevented by observing / obeying safety procedure / rule. This safety rule is intended to protect employee, user, equipment and building from danger and risk due to electrical effect. These rules are based on IEE (Institution of Electrical Engineers) regulation and Department of Electric and Gas Supply that have been updated from to time

The followings are safety procedures/ rules which must be obey: a) the floor of workplace must be free (clean) from oil, water and grease. These materials can cause the workers to slip as they work. b) Equipment used must in good and perfect condition. If not, report to officer in charge. All equipment must be kept at right and safe place so that it is easy to look for especially during emergency. After use, the equipment must be kept at its original place. c) Wear suitable clothing, not too tight and not too loose. Wear shoe having thick and all round sew sole when doing wiring work. Wearing slipper is strictly prohibited. d) Nobody is allowed to make joke or playing sharp instrument or object with friend while doing wiring work. e) Make sure the cable/conductor used fulfill its size (rating) and having suitable insulation. f) Make sure every electrical installation have effective earthing and avoid it from rust. g) Any addition of circuit must be avoided unless there is permission from officer in charge. h) Do not dismantle electric component/device used in the experiment without the knowledge of officer in charge. i) Assistance from officer in charge must be sought before testing the experiment with electrical supply. j)

After

using

electrical

machine,

it

must

be

switch

off.

k) In case any accident happened, officer in charge must be informed immediately. l) All electrical supply must off after finishing the job or before leaving laboratory. m) Before fitting plug to the socket, socket outlet switch must be in the off condition. n) Make sure environment around workplace is clean and systematic before and after work.

Satellite Communication.

How a satellite works A satellite is basically a self-contained communications system with the ability to receive signals from Earth and to retransmit those signals back with the use of a transponder—an integrated receiver and transmitter of radio signals The main components of a satellite consist of the communications system, which includes the antennas and transponders that receive and retransmit signals, the power system, which includes the solar panels that provide power, and the propulsion system, which includes the rockets that propel the satellite The Boeing 702 series of satellites, in contrast, can have more than 100 transponders, and with the use of digital compression technology each transponder can have up to 16 channels, providing more than 1,600 TV channels through one satellite. Satellite communications use the very high-frequency range of 1–50 gigahertz (GHz; 1 gigahertz = 1,000,000,000 hertz) to transmit and receive signals. The frequency ranges or bands are identified by letters: (in order from low to high frequency) L-, S-, C-, X-, Ku, Ka-, and V-bands. Signals in the lower range (L-, S-, and C-bands) of the satellite frequency spectrum are transmitted with low power, and thus larger antennas are needed to receive these signals. Signals in the higher end (X-, Ku-, Ka-, and V-bands) of this spectrum have more power; therefore, dishes as small as 45 cm (18 inches) in diameter can receive them. This makes the Ku-band and Ka-band spectrum ideal for direct-to-home (DTH) broadcasting, broadband data communications, and mobile telephony and data applications. Wiring Systems. It is the electrical wiring and associated devices such as switches, meters and light fittings used in buildings or other structures. There are three different types of wiring systems 1. Conduit wiring systems- which is further divided into conduit surface and concealed conduit

2. Trunking wiring systems. 3. Surface wiring systems. Conduit wiring systems Cables are being laid through the conduit which is concealed and embedded in the wall.

Advantages of conduit wiring 1. It provides mechanical attention. 2. It is neat and accurate.

Disadvantages of conduit wiring 1. It is very expensive. 2. It takes time to install. 3. It is difficult to access when faulty. Trunking wiring systems It is similar to the conduit wiring system just that it is not concealed to the wall

Advantages of trunking 1. It is flexible. 2. It provides a means of mechanical protection.

Disadvantages of trunking 1. It can easily be damaged due to exposure. Surface wiring system The wires are just passed on the surface of the wall

Advantages of surface wiring 1. It is very cheap. 2. It is flexible. 3. The installation time is short. 4. It is easy to access.

Disadvantages of surface wiring 1. When badly done it could deface the whole area.

Factors to consider when choosing wiring systems 1. Surrounding 2. Cost Cable It is two or more wires running side by side and bonded, twisted, or braided together to form a single assembly

Factors to consider when choosing cable 1. Current rating 2. Length of run 3. Environmental temperature 4. Class of protection

Cable series 1mm2

8A-12A

1.5mm2

12A-22A

2.5mm2

22A-33A

4mm2

33A-45A

6mm2

45A-60A

ETC

Cable description The cross sectional area of the cable is considered first then the conductor cores, insulation type kind of protection and the voltage passing through

Cable colour codes Red/brown-live Blue/black-neutral Yellow/green-earth Point of a light

Accessory Requirement PVC Box to install the Light Switch-01 nos

One Gang Light Switch-01 nos Junction box Lamp Holder-01 nos MCB 6A -01 nos [from a distribution board already installed

Method of Wiring Make sure that the power is isolated [shut down] to the Distribution board or any circuit you will be working with. Connect the Phase [L] wire to the outgoing side of a 6A or a 10A [Maximum] MCB from the Distribution Board [DB]. Draw the Phase wire to the Switch box and connect to one terminal. Connect another Phase wire to the remaining terminal of the switch and draw it to the junction box position and connect to one of the 3 terminals of the junction box. Connect the Neutral [N] wire to the Neutral Link provided in the DB. It is good practice to number the Phase and the Neutral wires at the DB for easy identification as one circuit. Connect the Earth [E] wire to the Earth link provided in the Distribution Board. Draw these Neutral and Earth wires directly to the junction box and use the two spare terminals to connect these wires separately. Now all the 3 terminals of the junction box are connected. Take the lamp holder and a short length of 3 core flexible cable and connect the Phase and Neutral wires to the holder. If the holder is a pin type one, then either the Phase or the Neutral can be connected to any terminal. If the holder is Screw type, then the Neutral should be connected to the threaded part of the terminal and the Phase to the other terminal. Normally the Earth wire is used for a Lamp fitting with metal parts to be connected. Then connect the Phase, Neutral and Earth wires of the flexible wire of the Lamp holder to the Ceiling rose to correspond to the L, N and E respectively. Bill of Engineering Measurement and Evaluation (B.E.M.E) This a table where the cost and quantity of engineering 40materials that are used is being recorded

s/n 1 2 3 4 5 6 7

Material description 2 gang switch 25mm2 b core flat 60 watt bulb Lamp holder Junction box 13 amp socket Patress

quantity

rate

Amount

1

100

100

2m

150

300

2

60

120

2

80

160

1

50

50

2

400

800

8

60

480

Computer Architecture

Parts of the CPU. RAM: it is for enhancing the speed of the system. Extension slot: it is used to extend the capability of the system. ROM: to enhance the speed of the system. SATA cable: it is used to connect the mother board to the hard disk. CMOS battery; it is the power back up for the time and date of your system Extension box

Materials PVC Box to install the Light Switch-01 nos

Double Gang Light Switch-01 nos Junction box Lamp Holder-01 nos MCB 6A -01 nos [from a Distribution Board already installed Socket-04nos

Method of wiring You first carve out the wood you want to use in the production. You then get all the required material. The wood is then scraped to make it smooth so that it can easily fit when assembling all the part required. The wood is then chiselled to make space for the socket and the switch to enter. The live wire is then connected from one socket to the other so is the neutral and earth. Then they are connected to a switch which in turn is jumped to the second switch which is for the light bulb and then the wires are also jumped to the bulb. After this connection the wire is then connected to the external cable which is then connected to the source of electricity. PETROLEUM ENGINEERING. On the first day we started with introduction and explanation on the purpose of the program. The lecturers of both departments (Chemical & Petroleum) introduced themselves and introduced us to the products we were going to produce which was paint for the chemical department and three products from petroleum department which includes petroleum jelly, hair cream and methyl bam. The next day the lecturers began explanation on the production of paints. Paints Paint is a term used to describe a number of substances that consist of a pigment suspended in a liquid or paste vehicle such as oil or water. With a brush, a roller, or a spray gun, paint is applied in a thin coat to various surfaces such as wood, metal, or stone. The production of paint involves three major components which are: 1. Binder

2. Solvent 3. Pigment Binder They are used to bind component, they are usually resins, and resins helps the paint dry. They include;

Natural They are elastic and gotten from the bark of trees. The natural resins most commonly used are line-seed, coconut, and soya bean oil.

Synthetic They are formulated from organic component. Alkyds, acrylics, epoxies, and polyurethanes number among the most popular synthetic resins. Solvents Solvents make paints easier to apply. Solvents are various low viscosities, volatile liquids. They include petroleum mineral spirits and aromatic solvents such as benzoyl, alcohols, esters, ketones, and acetones.

Specific gravity and cost Flash point of a solvent It is the temperature of the liquid at which a mixture of its solvent vapour and air can ignite at the presence of a spark. The higher the flash point of a solvent the safer the solvent is in storage tank liquids of low flash points is volatile Pigments The pigments give the paint colour. There are different pigments, both natural and synthetic, exist. The basic white pigment is titanium dioxide, selected for its excellent concealing properties, and black pigment is commonly made from carbon black. Other pigments used to make paint include iron oxide and cadmium sulphide for reds, metallic salts for yellows and oranges, and iron blue and chrome yellows for blues and greens. Extender They improve the strength of the paint film. Serve as adhesives to the film. Solvent based extenders and polymer dispersion extenders, also known as emulsion adhesive. As the solvent evaporates the extender become stronger. There are two secondary components which are: 1. Extender

2. Additives Additives They used to fulfil a specific purpose in painting. Additives serve as everything from fillers to ant fungicidal agents. Additives serve many purposes. Some, like calcium carbonate and aluminium silicate, are simply fillers that give the paint body and substance without changing its properties. Other additives produce certain desired characteristics. For example, it helps improve the opacity of the paint which is the ability of paint to cover a surface Paints are applied to fulfil two primary purposes which are 1. Protection 2. Beautification There are mainly two types of paints which are 1. Emulsion- which is water based paint. 2. Gloss- which is oil based paint. Paint troubleshooting  Peeling Paint curls due to wet wood, interior moisture vapour, dirty, glossy surface.

Solution Scrape, sand, prime, repaint. Install siding/soffit vents outside, exhaust fans inside.  Wrinkling New paint sags and droops. Paint applied too thickly.

Solution Scrape, sand, prime, and repaint. Stir new paint and brush out thoroughly.  Alligatoring Paint dries into islands. Either due to incompatible paints or painting too soon over stillwet coat.

Solution Scrape, sand, prime, and repaint with a compatible coating.  Blistering Surface blisters caused by underlying moisture or solvent from paint applied on hot day.

Solution Sand smooth, repaints. Install vents. Paint on mild days.  Chalking Powdery residue stains on sidewalks, foundations. Inferior paint or porous undercoat is to blame.

Solution Wash down surface, let dry, and repaint with no chalking coating.  Mildew Discoloration of exterior surface due to growth of fungus, usually black/green stains.

Solution Scrub off with chlorine bleach or fungicide, let dry, and repaint with mildew-resistant formula. Trim tree branches, shrubs.  Running sags Wavy paint surface. Paint applied too heavily.

Solution Sand smooth, repaints. Brush out paint to a consistent thickness.  Paint won't dry Inferior paint.

Solution Patience or removing and then repainting. Test paints on small areas before painting entire house.  Efflorescence Whitish deposits on masonry caused by morsel rusting nail heads with rust-resistant sealer and paint entire surface-induced oxidation.

Solution Scrub off deposits with 10:1 water-muriatic acid solution, followed by 2:1 waterammonia, water rinse, dry, repaint with appropriate masonry paint. Check downspouts, eliminate damp conditions.  Rust-stained siding/shingles Rusting nail heads, gutters sealed insufficiently.

Solution Seal rusting nail heads with rust-resistant sealer and paint entire surface.  Rusted metal Deteriorated paint combined with moisture.

Solution Scrape, sand, recoat with metal primer, metal paint.  Bleeding knots Knot resin dissolved by paint solvent from improperly sealed, primed knots.

Solution Scrape, sand to bare wood, coat with shellac, prime, repaint. Manufacturing processes Water of about 650ml is put into the bowl. Pigment of any colour is added but not added when its white paint you intend to produce. Titanium dioxide of about 75g is then added. If it is textural paint you intend to produce you add marble dust of about 400g. 650ml of calcium carbonate is then added 10ml of antacids is then added 10ml of genepour is added. 10ml of formaldehyde is added 10ml of defoamer is added 175g of acrylic is added then you stir the mixture well before adding the binder nitrosol of about 12g. Petroleum Jelly. Petroleum jelly is made by the waxy petroleum material that formed on oil rigs and distilling it. The production of petroleum jelly involves the use of four major components which are: 1. Petroleum jelly 2. Paraffin oil 3. Lanolin 4. Fragrance  Petroleum jelly This is the main component in the production of petroleum jelly. It is a mixture of hydrocarbons, having a melting point usually within a few degrees of human body temperature. It is flammable only when heated to liquid, and then the fumes will light, not the liquid itself, so a wick material like leaves, bark, or small twigs is needed to ignite petroleum jelly. It is colourless, or of a pale yellow colour (when not highly distilled),

translucent, and devoid of taste and smell when pure. It does not oxidize on exposure to the air and is not readily acted on by chemical reagents. It is insoluble in water. It is soluble in dichloromethane, chloroform, benzene, diethyl ether, carbon disulphide and oil of turpentine.  Paraffin oil Paraffin oil is used to store flammable element. It is used to keep the petroleum jelly from easily igniting. It is a flammable liquid hydrocarbon burned as fuel. It is most commonly used to power jet engines for aircraft, but can also be used for heating, lighting, and cooking. It is refined from petroleum and is relatively cheap to produce.  Lanolin It is also called wool wax or wool grease. It is a yellow waxy substance secreted by the sebaceous glands of wool bearing animals. Most lanolin used by humans comes from domestic sheep breeds that are raised specifically for their wool. It is used commercially in many industrial products ranging from rust proof coatings to lubricants.  Fragrance Fragrance is a minor component in the production of petroleum jelly. It is used mainly to give the jelly a good smell. It is used for many other purposes. Uses of petroleum jelly  Medical treatment Petroleum jelly is used to prevent skin burns, scrapes and cuts mostly during in cold weather conditions.  Skin care Most petroleum jelly today is used as an ingredient in skin lotions and cosmetics, providing various types of skin care and protection by minimizing friction or reducing moisture loss, or by functioning as a grooming aid.  Product care and protection Petroleum jelly can be used to coat corrosion-prone items such as metallic trinkets, nonstainless steel blades, and gun barrels prior to storage as it serves as an excellent and inexpensive water repellent. It is used as an environmentally friendly underwater antifouling coating for motor boats and sailing yachts.  Production processes Petroleum jelly is a useful material when incorporated into candle wax formulas. The petroleum jelly softens the overall blend, allows the candle to incorporate additional fragrance oil, and facilitates adhesion to the sidewall of the glass.

Disadvantages of using petroleum jelly  Skin irritations The problem with petroleum products, instead of moisturizing, it coats the skin and clog the pores not letting in actual moisture and toxins out through the skin. The skin may feel smooth to the touch, but it‘s actually coated with the oil. As a result, it can cause acne, dryness, dandruff and other skin irritations.  Skin cancer The impurities in petroleum jelly which is known as petrolatum is known to cause breast cancer Manufacturing Process Petroleum jelly95% Fragranceas required Lanolin 2% paraffin oil2% Depending on the quantity you want to produce that‘s why it is written in percentage form. Add 95% of petroleum jelly in a metal container followed by 2% lanolin and 2% paraffin oil. Heat the mixture using dry heat, until it melts completely then add your preferred fragrance to a desired quantity. Once you are done with that pour the product into a container allow to cool. Now you have your petroleum jelly ready to use. Hair Cream. Hair creams are hair moisturisers that help prevent the air from external damage it also assists in hair growth. The production of hair cram involves the uses of five major components, namely: 1. Petroleum jelly 2. Paraffin oil 3. Lanolin 4. Fragrance 5. Colorant And one minor component which is the additive

 Colorant This is used in the coloration of the hair cream mainly to make it attractive to customers.  Additive The additive is used to fulfil a specific purpose in making of hair cream. Additives serve as everything from fillers to ant fungicidal agents. Uses of hair cream  Hair care Hair creams provides moisture to dry or damaged hair from the roots to the very tips, repairing and protecting against weather damage, dryness and brittleness. It also absorbs quickly and completely into the scalp to rehydrate without clogging pores.  Medical purposes Hair creams are often used to treat and prevents irritations like dandruff by moisturizing the hair and keeping lies away from it. It is an excellent treatment for dry scalp. It restores lustre to damaged hair.  Protection Its therapeutic properties protect the skin from wind, cold, sun and it helps heal wounds faster.  Cellular activities Hair cream stimulates cellular activity, fights the effects of aging and repairs rough, damaged skin.

Disadvantages of using hair cream  Hard hair The disadvantage of using hair cream is, if you apply too much daily, you get a result of dry scape, flakes, frizzes, hard, and even cause your hair to break off a little. Manufacturing Process Steep your additives of choice in eight grams of liquid oil (Paraffin oil) for three to six weeks. This oil will condition and lubricate your skin and hair, and then depending on the additives you infuse in them, you will receive additional benefits. Some examples of additives you can use include lavender, which is antimicrobial and aromatic, and calendula, which can help soothe flaky skin and irritated scalps. Strain out the additive and measure in six grams, the oil for your cream.

In a double boiler, warm and stir the liquid and solid oils along with the additives until they melt and form a uniform liquid. Remove the mixture from the heat, and let it stand at room temperature until it cools to the touch, stirring it to keep the consistency even. Warm the nine ml of liquid to body temperature, and put it in the blender along with 1/4 tsp. of powdered vitamin C and a couple of drops of grapefruit seed extract, both of which will act as preservatives for the cream. Turn the blender on high speed, and slowly add the oil mixture until you achieve a thick and creamy paste. Stir in the essential oils, and pour your cream into a sterilized jar, capping it with a tightfitting lid. Let the cream sit overnight so the ingredients can set thoroughly. Methyl Balm This is any of various oily, fragrant, resinous substances, often of medicinal value, exuding from certain plants, especially tropical trees of the genus. The production of methyl balm involves the use of four major components which are: 1. Petroleum jelly 2. Paraffin oil 3. Paraffin wax 4. Methanol  Paraffin wax Paraffin wax, classified as a chemical preservative, is widely used on fruits, vegetables, and candy to make them shiny and pretty as well as to retard moisture loss and spoilage. It is a white or colourless soft solid derivable from petroleum, coal, or shale that consists of a mixture of hydrocarbon molecules containing between twenty and forty carbon atoms.  Methanol This is what gives the balm its minty odour.it is toxic in the body but very useful outside the body.

Uses of balm  Medicinal purposes Methyl balm is used to cure fractures and dislocated joints. It‘s also used to reduce body swellings. It‘s used to reduce running noses.  Protection It is used during cold weathers to reduce the risk of getting deadly diseases like pneumonia which can lead to death Disadvantages of using methyl balm It is very dangerous when apply to delicate part of the body such as the eye. When applied in excess it can cause skin inflammation Manufacturing Processes Measure 1100 ml of petroleum jelly. 150ml of paraffin oil. 100ml of methanol and 200ml of paraffin oil After setting the heat system, place the clean metallic boiler on it. Add petroleum jelly in the stated amount of according to you own formulation. Now heat for at least two minutes and add paraffin oil in the required amount of, stir very well for complete and add these homogenization and add the other chemicals at one minute interval; methyl crystal (usually in flakes form), methanol, turpentine and add Paraffin oil and continue stirring. Now set apart little quantity of the mixture using a small container and allow cooling to test for the desired texture, if it is very watery, add small quantity of paraffin wax and continue heating till you get your desired texture.

MECHANICAL ENGINEERING At this department, we were first taught the ―safety precautions‖ to maintain at the various workshops. Some of which were:  Free access to the workshop areas is restricted to authorised personnel only. No other person may enter the workshop without permission.  No machine may be used or work undertaken unless the technician-in-charge is satisfied that the person is capable of doing so safely. If equipment is fitted with guards these must be used. Equipment should never be used if the safety guards have been removed.

 Any person working in the mechanical workshop must have read and signed the appropriate risk assessment if the work or equipment they are using has been risk assessed.  Personal Protective Equipment (PPE) is provided and must be used where necessary. Barrier cream, lab coats, safety glasses/goggles and safety shoes are to be used as the work dictates. When working with machine tools or other equipment with rotating spindles, jewellery, loose clothes etc. are prohibited and long hair must be completely covered.  Machine tools, plant and equipment must be serviced and kept.  No hazardous substance to health can be used before a COSHH risk assessment is undertaken and a safe system of work issued to the users.  No person shall mount any abrasive wheel unless he/she has been trained in accordance with the Abrasive wheel. Do not carry loads such that the weight may be dangerous or vision obscured. Report any defective equipment to the technician-in-charge. Smoking, eating and drinking in workshop areas is strictly prohibited. The gangway through the workshop must be kept clear. Any oil spillage, grease etc. must be cleaned up immediately.  Equipment must be cleaned after use. Any materials, tools or equipment used must be tidied away.  Precision measuring equipment, drills, etc. must be replaced in their appropriate cabinets after use.  All accidents/incidents/occupational ill health must be reported.  In the event of a fire, leave the building immediately. Then, we were taught on the various machines in the labs and their uses.    

 MACHINE WORKSHOP



Lathe Machine

Fig 1.0 A Lathe machine is a tool that rotates a work piece on its axis in order to perform various operations. Tools are applied to the work piece to create an object having a symmetrical axis of rotation in order to perform actions including cutting, sanding, knurling, boring, drilling or deformation, facing and turning. Woodturning, metalworking, metal spinning, thermal spraying/ parts reclamation and glass-working are common applications of lathe machines. A lathe machine can also be used to shape pottery as well. This is one reason why it is commonly known as the potter's wheel. Lathe Machines in India has come about popularly especially because Indians are known for their pottery. Moreover, the growth in the industrial sector in India has also given rise to Lathe Machines India. Lathe Machines truly play a vital role in the industrial revolution in India as well as in the rest of the world. We provide the best quality Lathe machines that are not only easy for the user to operate but also act as a friendly companion of the environment

Parts of the lathe machine. Head Stock Bed Tail Stock  HEAD STOCK It comprises of the spindle and the chuck. There are two types of chucks, namely; A. 3 jaw-chuck B. 4 jaw-chuck The difference being that, when opening the 3 jaw-chucks with the chuck key, all the jaws open at once.

While In the case of the 4 jaw-chuck, the jaws have to be opened individually.  BED It comprises of a carriage on which there is a saddle. On the saddle rests the cross-slide, on which rests the compound rest. This component is where the cutting tool is held in position.  TAIL STOCK This part of the machine is responsible for holding the work piece firmly at the other end.

Processes carried out on a lathe machine (i) Facing: This operation is almost essential for all works. In this operation, as shown in fig 1.0 the work piece is held in the chuck and the facing tool is fed from the centre of the work piece towards the outer surface or from the outer surface to the centre, with the help of a cross-slide.

(ii) Plane Turning: It is an operation of removing excess amount of material from the surface of the cylinder work piece. In this operation, the work is held either in the chuck or between centres & the longitudinal feed is given to the tool either by hand or power. (iii) Step Turning: It is an operation of producing various steps of different diameters of in the work piece as shown in fig. This operation is carried out in the similar way as plain turning. (iv)Drilling: It is an operation of making a hole in a work piece with the help of a drill. In this case, the work piece is drilled by rotating the tail stock hand wheel. The drill is fed normally, into the rotating work piece, by rotating the tail stock hand wheel. (v) Boring: This operation involves making a hole or depression on a work piece.



Milling Machine

Milling is the process of machining flat, curved, or irregular surfaces by feeding the work piece against a rotating or cutter containing a number of cutting edges which. The milling machine consists basically of a motor driven spindle motors, mounts and revolves the milling cutter, and a reciprocating adjustable worktable, which mounts and feeds the work piece Milling machines are basically classified as vertical horizontal. These machines are also classified as knee-type, ram-type, manufacturing or bed type, and planer-type. Milling machines have self-contained electric drive coolant systems, variable spindle speeds, and power-operated. 

Drilling machine

A drilling machine comes in many shapes and sizes, from small hand-held power drills to bench mounted and finally floor-mounted models. They can perform operations other than drilling, such as counter-sinking, counter boring, reaming, and tapping large or small holes. Because the drilling machines can perform all of these operations, this chapter will also cover the types of drill bits, took, and shop formulas for setting up each operation. Safety plays a critical part in any operation involving power equipment. This chapter will cover procedures for servicing, maintaining, and setting up the work, proper methods of selecting tools, and work holding devices to get the job done safely without causing damage to the equipment, yourself, or someone nearby

 AUTOMOBILE WORKSHOP An automobile repair shop (also known as a garage) is a repair shop where automobiles are repaired by auto mechanics and electricians

Operations carried out in the automobile workshop  Changing of suspension This involves removing the tire and then the suspension. First of all, slack the tire you want to remove. You then wedge the tire diagonal to the tire you are removing, and then you get your jack in order to raise the tire, and then completely remove the tire Then, remove the upper strut-mount nuts and bolts, but leave the centre strut shaft nut in place or disaster will follow (the compressed spring will shoot like a rocket). Using the spring compressor, compress the spring to take pressure off the upper strut mount. Then, loosen the shaft nut to remove the upper strut mount. You the repeat the process in reversed order  Servicing an engine This mainly involves checking four major components of the engine such as;    

Engine oil Oil filter Spark plug Air filter

Engine Oil Let's start with the engine oil change. The engine oil needs to be warm before draining, as warm oil will flow more freely than cold. Run the engine for 15 minutes or so before drainage. Ensure you perform the oil change on a level surface. Jack the car up and axle stands for safety. Remove the oil cap on the top side of the engine. Failure to do this may cause a vacuum when draining the oil, resulting in not all the oil being removed. Place the oil catch pan under the sump plug and drain. The engine oil may be hot.

Oil Filter Turn the oil filter wrench anti-clock wise to remove the filter. The filter may still have plenty of oil inside so be careful not to spill it.

Ensure the filter seat on the engine is clean and place a light coating of oil on the gasket of the new filter. Initially screw the oil filter back on and gently tighten with the oil filter wrench. Ensure not to over-tighten for risk of damaging screw thread.

Spark Plug Before removing the old spark plugs, ensure there is no debris around the chamber that may fall into the ignition chamber. Using a good quality brand with copper core electrodes, insert the plugs until hand-tight. Continue to tighten the plugs with the spark plug removal tool for a further 1/4 to 1/2 turn of the tool ensuring that you don't overtighten as this may result in thread damage.

Air Filter Fitting a new air filter is a simple process. The air filter housing may be secured by screws or simply clipped on. The new air filter simply needs to be dropped in. Other checks are to be done on the brake fluid steering fluid and other hydraulic fluids. We were then shown several car components, such as: ―Propeller shaft, Suspension spring, Crank shaft, Driven shaft, Vices, Paedophile, Grinder, Gear box, Radiator, Brake pad, Shock absorber, Governor, Gasket, Water pump, Piston, Block engine, Lower arm, Cylinder head, Gears, Exhaust pipe, Brake salvo, Fuel filter, Gear train, Alternator‖ We were also taught that in the cylinder, there are four strokes, namely: 1. Inlet stroke 2. Compression stroke 3. Power stroke 4. Exhaust stroke The order in which these strokes occur in the cylinder is based on their Firing order. E.g. 1423.  FOUNDRY WORKSHOP

The foundry and lathe machines.

A foundry is a factory that produces metal objects called castings. Metals are cast into shapes by melting them into a liquid, pouring the metal in a mould, and removing the mould material or casting, after the metal has solidified as it cools. Departments under Foundry Workshop 1. Design Room/Shop: This is where designs are made. 2. Pattern Section: Here, there is a pattern maker. He works majorly with wood because it is cheap and available. A pattern is a replica of what is to be casted. Without pattern the hollow mould cannot be derived. 3. Sand Preparation: This is the shop in which moulding sand is produced.

A. B. C. D. E.

Composition of moulding sand Silica sand: It is used as base when combining sands. It can also withstand heat and has the highest composition. Bentonite: It is treated clay. In the absence of bentonite, normal clay can be used or starch. Coal dust: It helps gas escape. It also helps the moulding sand collapse. Water: Acts as solvent. Moulding box: It is rectangular and comes in pairs called ―DRAG and COPE‖ When creating the mould, parting sand must be put between the drag and cope so that they do not stick together. Casting

  Sand casting Sand casting, the most widely used casting process, utilizes expendable sand moulds to form complex metal parts that can be made of nearly any alloy.

 Mould-making The first step in the sand casting process is to create the mould for the casting. In an expendable mould process, this step must be performed for each casting. A sand mould is formed by packing sand into each half of the mould. The sand is packed around the pattern, which is a replica of the external shape of the casting. When the pattern is removed, the cavity that will form the casting remains. Any internal features of the casting that cannot be formed by the pattern are formed by separate cores which are made of sand prior to the formation of the mould. Further details on mould-making will be described in the next section. The mould-making time includes positioning the pattern, packing the sand, and removing the pattern. The mould-making time is affected by the size of the part, the number of

cores, and the type of sand mould. If the mould type requires heating or baking time, the mould-making time is substantially increased. Also, lubrication is often applied to the surfaces of the mould cavity in order to facilitate removal of the casting. The use of a lubricant also improves the flow the metal and can improve the surface finish of the casting. The lubricant that is used is chosen based upon the sand and molten metal temperature.  Clamping Once the mould has been made, it must be prepared for the molten metal to be poured. The surface of the mould cavity is first lubricated to facilitate the removal of the casting. Then, the cores are positioned and the mould halves are closed and securely clamped together. It is essential that the mould halves remain securely closed to prevent the loss of any material.  Pouring The molten metal is maintained at a set temperature in a furnace. After the mould has been clamped, the molten metal can be ladled from its holding container in the furnace and poured into the mould. The pouring can be performed manually or by an automated machine. Enough molten metal must be poured to fill the entire cavity and all channels in the mould. The filling time is very short in order to prevent early solidification of any one part of the metal.  Cooling The molten metal that is poured into the mould will begin to cool and solidify once it enters the cavity. When the entire cavity is filled and the molten metal solidifies, the final shape of the casting is formed. The mould cannot be opened until the cooling time has elapsed. The desired cooling time can be estimated based upon the wall thickness of the casting and the temperature of the metal. Most of the possible defects that can occur are a result of the solidification process. If some of the molten metal cools too quickly, the part may exhibit shrinkage, cracks, or incomplete sections. Preventive measures can be taken in designing both the part and the mould and will be explored in later sections.

 Removal After the predetermined solidification time has passed, the sand mould can simply be broken, and the casting removed. This step, sometimes called shakeout, is typically performed by a vibrating machine that shakes the sand and casting out of the flask. Once removed, the casting will likely have some sand and oxide layers adhered to the surface.

Shot blasting is sometimes used to remove any remaining sand, especially from internal surfaces, and reduce the surface roughness.

 Trimming During cooling, the material from the channels in the mould solidifies attached to the part. This excess material must be trimmed from the casting either manually via cutting or sawing, or using a trimming press. The time required to trim the excess material can be estimated from the size of the casting's envelope. A larger casting will require a longer trimming time. The scrap material that results from this trimming is either discarded or reused in the sand casting process. However, the scrap material may need to be reconditioned to the proper chemical composition before it can be combined with nonrecycled metal and reused. 4. Scrap Yard: This is the unit where a slap is produced. A slap is that waste/residue can be used to carry out another process. Slaps Needed in Foundry METAL

TEMPERATURE

Cast Iron

1350

Copper

950

Brass and Bronze

900

Aluminium

650

Zinc

300

850

5. Furnace: This is a chamber that produces heat in order to melt metals into liquid. Types of Furnace.  Crucible Furnace: It has crucible pot within it. It has a diesel tank and blower for producing air for cooling. Diesel is also spread within it for continuous burning. The place where air and diesel meet is called the ‗burner‘ and this is where combustion also takes place.  Rotary Furnace.  Cupola Furnace.  Induction Furnace. The thermocouple is used to determine the temperature of the furnace. Impurities that float on top after boiling are called ‗slag‘.

6. Machine Shop: This is where finishing work is done on the cast. Sand is majorly used in foundry because it can withstand high temperature. WELDING WORKSHOP Welding is a dependable, efficient and economic method for permanently joining similar metals. In other words, you can weld steel to steel or aluminium to aluminium, but you cannot weld steel to aluminium using traditional welding processes.

Types of welding 

Shielded Metal Arc Welding (SMAW)

SMAW is a welding process that uses a flux covered metal electrode to carry an electrical current. The current forms an arc that jumps a gap from the end of the electrode to the work. The electric arc creates enough heat to melt both the electrode and the base material(s). Molten metal from the electrode travels across the arc to the molten pool of base metal where they mix together. As the arc moves away, the mixture of molten metals solidifies and becomes one piece. The molten pool of metal is surrounded and protected by a fume cloud and a covering of slag produced as the coating of the electrode burns or vaporizes. Due to the appearance of the electrodes, SMAW is commonly known as ‗stick‘ welding. DISADVANTAGES (1) It produces a lot of smoke & sparks, (2) There is a lot of post-weld clean-up needed if the welded areas are to look presentable, (3) It is a fairly slow welding process and

(4) It requires a lot of operator skill to produce consistent quality welds. 

Gas Metal Arc Welding

In the GMAW process, an arc is established between a continuous wire electrode (which is always being consumed) and the base metal. Under the correct conditions, the wire is fed at a constant rate to the arc, matching the rate at which the arc melts it. The filler metal is the thin wire that‘s fed automatically into the pool where it melts. Since molten metal is sensitive to oxygen in the air, good shielding with oxygen-free gases is required. This shielding gas provides a stable, inert environment to protect the weld pool as it solidifies. Consequently, GMAW is commonly known as MIG (metal inert gas) welding. Since fluxes are not used (like SMAW), the welds produced are sound, free of contaminants, and as corrosion-resistant as the parent metal. The filler material is usually the same composition (or alloy) as the base metal. 

Gas Tungsten Arc Welding

In the GTAW process, an arc is established between a tungsten electrode and the base metal(s). Under the correct conditions, the electrode does not melt, although the work does at the point where the arc contacts and produces a weld pool. The filler metal is thin wire that‘s fed manually into the pool where it melts. Since tungsten is sensitive to oxygen in the air, good shielding with oxygen-free gas is required. The same inert gas provides a stable, inert environment to protect the weld pool as it solidifies. Consequently, GTAW is commonly known as TIG (tungsten inert gas) welding. Because fluxes are not used (like SMAW), the welds produced are sound, free of contaminants and slags, and as corrosion-resistant as the parent metal.

Tungsten‘s extremely high melting temperature and good electrical conductivity makes it the best choice for a non-consumable electrode. The arc temperature is typically around 11,000° F. Typical shielding gasses are Ar, He, N, or a mixture of the two. As with GMAW, the filler material usually is the same composition as the base metal. This was all that was learnt during the SWEP program.