N.U.S.

T INDUSTRIAL AND MANUFACTURING ENGINEERING

ATTACHMENT LOGBOOK

NATIONAL UNIVERSITY OF SCIENCE AND TECHNOLOGY

Faculty of Industrial Technology

Department of Industrial and Manufacturing Engineering

INDUSTRIAL ATTACHMENT LOG BOOK

BY
NAME OF TRAINEE: DUBE JAPHET

STUDENT NUMBER: N01310009J

DURATION: 15th AUGUST 2018 - 31st JULY 2019

ITA Logbook Kariba South Power Station (ZPC)

ORGANISATION : KARIBA SOUTH POWER STATION

INDUSTRIAL SUPERVISOR : Eng. T. MAZARIRE

ACADEMIC SUPERVISOR : Eng. B. SAREMA

DATE OF SUBMISSION: AUGUST 2019

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ACRONOMY
HR- Human Resources

PEM- Principal Engineer Maintenance

PES- Principal Engineer System

ACB- Air Circuit Breaker

TCW- Transformer Cooling Water

NWL- Normal Working Level

DC- Direct current

AC- Alternating current

ORTP- Operational Routine Test Procedure

V/V- valve

KSPS- Kariba South Power Station

Shld-Should

wld- would

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AUGUST 2018
Week Summary Activity Recommendations/ Supervisor
Lessons learnt Sign
(15- Induction  Student was introduced to company  Student learnt about Code of
18)-08- rules and regulations by the HR and conduct and organisational
2018 had induction with departments like structure at KSPS.
Operations, Mechanical, Electrical,
Finance, Loss control and IT during a
week period. HR explained the
following
 A code of conduct refers to
formulated, negotiated and
registered principles, ethics or
rules and laws (in terms of
section 101 of the labor relations
act chapter 28.01 of 1996) as
well as procedures which govern
the Zimbabwe Power Company
organization. The purpose of this
induction was to familiarize the
student to the expected behavior.
The code is divided into 3 parts
which are;
i) Disciplinary procedure –
describes rules and
disciplinary action taken
when those rules are
breached.
ii) Grievance procedure –

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channel which can be

followed when there is
dissatisfaction between
the employer and the
employee or between
employees.
iii) Business conduct policy –
response to all business
irregularities such as
fraud, bribery, corruption,
forgery or money
laundering which in most
cases lead to dismissal.
 The HR also explained the
composition of the Disciplinary
hearing, explaining that when an
individual has been summoned for a
hearing, he/she can choose any
member from the worker’s committee
to represent them but the Secretarial
position should be someone who is a
Legal practioner, because they better
understand and interpret the law and
all statues are resident with the
Human Resources. These do not have
any right to participate except to
preside over the proper proceedings
of the hearing.

(19- Induction-  The student took part in  The student learnt that every Supervisor
22)- (House- housekeeping in a 3-day period as the person at the organisation even Sign

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08- keeping ) last part of the induction process the last at the shop flow are very
2018. facilitated by the HR and respective important as they execute tasks
housekeepers at the plant. The tasks that make sure that the shop flow
involved were cleaning, gardening is always clean in a way of
and arranging of chairs in the meeting minimizing accidents at work
hall.. place.
 However, the student learnt that
making sure the shop flow is
clean is not only the
responsibility of those
employees in the housekeeping
but also anyone in the plant as
this is very effective way of
eliminating hazards and
accidents at the work place
Supervisor’s comment:
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Supervisor’s Signature: ……………………………DATE…………………………...

Student Signature…………………………………

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SEPTEMBER 2018
Week Summary Activity Recommendations / Supervisor
Lessons learnt Sign
10-09- Operations  Student was introduced to operations  The student learnt that some of the
2018 Department Shift Charge who handed over him functions of the operations department
to Senior Turbine operator, Mr are
Chipatiso to be part of Shift E. a) plant equipment monitoring and example of
 Student introduced to general plant equipment monitored are generators,
lay out. transformers, chillers etc.
b) isolations- particular isolation of plant
equipment can be done by Shift Charge
Engineer (e.g. generator isolation for
maintenance) and turbine operators (e.g.
mulsifire air compressors routines
maintenance by electrical department)
c) switching of equipment, generators are
switch off during off peak hours and later on
when the load becomes high.
 Student learnt about the general plant lay
out, which consists of the transformer
side, (transformers are grouped into 3
banks, 1, 3 and 5. Each transformer bank
have 3 single transformers with each for Supervisor
Red, Yellow and Blue phases) ventilation Sign
plant (the circulation of air in the plant is
controlled by the vent plant which
continuously blow air around the plant)
contains and generators side which
produces electricity.
11-09- Routes conducted  Student introduced to routine checks Supervisor
2018 by the operations conducted in every beginning of  Student understood the importance of Sign

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department each shift. taking readings every 30 minutes’

Some checks done at the beginning of each interval and these are some of the
shift are reasons;
a) TCHWL alarm checks.
b) Brake test a) The information recorded can be used
c) Switch gear air compressors for future referencing purpose.
drainage of condensate from air b) The information can be used to
reservoir comparison purpose with the new
d) HWL alarm checks on the drainage plant
pits c) Information recorded can be useful in
e) TCW pits checks route cause analysis to determine the
f) Draining of brake air compressors orientation of equipment failure.
reservoir d) Information can be useful in early
g) Brake air isolator valve exercising. detection of equipment failures
(isolator valve must be always
closed)
h) Lighting boards checks
 Student learnt to take readings
taking every 30 minutes
Challenges faced in taking
readings
Student had challenges 1st time in taking the
required readings in the 30 minutes intervals
but later managed with the help of the
turbine operator.

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Week Summary Activity Recommendations/ Lessons Learnt Supervisor

Sign
15-09- Adding oil to  The student with the help of a senior  Student learnt that the accumulator piston
2018 Governor sump to Artisan top up oil to the required normal should be kept around 63.3% and 74%
the required working level (NWL) for effective control of guide vanes.
Normal Working The procedure was as follows;
Level, (NWL).
i) No isolation (generator kept
running)
ii) Adding oil in the governor sump
using a 20L container of oil.
iii) Constant checking on the
accumulator digital display for
required level of the piston, in
which the expected percentage
was to fall within the range of
63.3% to 74% piston movement.

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Precautions or requirements in executing Supervisor

the tasks; Sign
i) Effective communication
between the person adding oil
and the person checking the
digital display for the minimum
and maximum piston percentage
movement.

19-09- Plant Protection  Student took part in checking plant  The student learnt that plant protection is Supervisor
2018 system protection system; controlled by protection relays and control Sign
 The plant has Generator protection relays supplied by 220V DC or 240DC
system and Generator Transformer because control devices need DC not AC.
protection (GTx) AC constantly changes direction each second
 Examples of GTx protection are; making it difficult to be used in control systems.
i) Buchholz relay
ii) OTI and WTI
iii) Frangible disk type (pressure
relief device)
 Generators are protected by Over speed
devices (mechanical and electrical over
speed devices)
20-09- Transformer  The student took routine checks on the  Student learnt that GTx transformers uses the Supervisor
2018 protection GTx side of the plant: mulsifire system to protect them from Sign
Example of monitoring system on the GTx transformer fires, and contains the detector
side are, system (a mercury bulb explode when
i) Mulsifire system pressure temperatures reach around 70 bars.
gauges checks for pressures of
about 70 bars.
ii) Exercising of pressure valves  Student identified that the mulsifire

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iii) Checks on duty compressor,
either compressor 1 or 2.
iv) Student could identify
compressor which is selected for
duty and drain air reservoir to
check if the compressor can
automatically cut in at stated  Student understood why the transformers are
pressure of around 40bars and
cut out pressure of around 80
bars as indicated by red
markings on the pressure gauges.
system can be prone to air leakages due
to aging of pipes which might
compromise the mulsifire efficiency
separated by a wall made of refractory
material to prevent spread of fire when one
transformer catch fire as each transformer is
between two refractory walls.

 However, the student identified the 21st

century methods of transformer protecting
device system uses a nitrogen injection
system. This system is to extinguish external
oil fires on transformer top due to tank
explosions and fire during internal faults.

Supervisor’s comment:
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Supervisor’s Signature: ……………………………DATE…………………………...

Student Signature…………………………………

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OCTOBER 2018
Week Summary Activity Recommendations/ Supervisor
Lessons Learnt Sign
19-10- Transformer cooling  Student took part in checking  Student learnt how
2018 System TCW pits for water levels in the transformers are cooled by
pits and checking for suspension water tapped from spiral
of oil in the pits. casing as summarised;
 Student check on condition of Water is tapered from the common
valves that supply the TCW pipe into particular transformer
system. units, 1, 3 and 5.
Water which is at a lower
temperature than oil, gains heat
from oil in a shell and tube heat
exchanger.
The hotter water is directed
through a separate return pipe into
individual TCW pits where it is
drained into draft tubes to the surge
chambers for disposal into Zambezi
River.
 Student learnt that a
suspension of oil in TCW

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pits shows that oil and Supervisor

water have mixed during Sign
heat exchange in the shell
and tube heat exchanger.
When such conditions are
notified, T/O are expected
to inform mechanical
department or electrical for
maintenance to take place.
 However, the student learnt
that the water levels in
TCW pits gives information
about the condition of the
transformer;
i) Generally, high water
level (less than a HWL
alarm set for particular
pit) shows that
transformer windings
are heating up and more
water is drawn from
spiral casing and
circulated to cool the Supervisor
oil. Sign
ii) Low water levels
(above the set LWL
alarm) shows that
transformer windings
temperatures are falling
below expected
temperatures.

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ITA Logbook Kariba South Power Station (ZPC)
Week Summary Activity
22-10- ORTP  Student took part in conducting
2018 ORTP #13 Governor pump
change over
 Student rotated control selector from
duty pump to standby pump.
25-10- ORTP # 8 Checking flow rate sensors for
2018 TCW
 Student did ORTP # 8 with the help of
turbine operators checking flow rate
sensors in meter gauges that taps from
spiral casing for cooling bearings.
 Student depressed button that gives
out an alarm showing that the flow
meter sensor is in normal working
condition.
Supervisor’s comment:
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Supervisor’s Signature: ……………………………DATE…………………………...
J. Dube IME 2018-2019
Recommendations/ Supervisor
Lessons Learnt Sign
 Student learnt how to do ORTP # 13
and this done weekly every Monday.
 The student appreciated the
importance of the preventive actions
taken to determine the availability of
standby pumps in a way of increasing
machine availability and overall
effective efficiency.
 Student understood that flow meters
might be malfunctioning giving wrong
reading on the display and this causes
bearing temperatures to be generally
high than the normal working
temperatures of around 60 degrees.
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Student Signature…………………………………

NOVEMBER 2018
Week Summary Activity Recommendations/ Supervisor
Lessons learnt Sign
06-11- Governor system  Student introduced to the speed  Student learnt that the speed
2018 and over speed governor and over speed devices governor is to regulate speed of
devices turbines by controlling the opening
or closure of guide vanes. The
control mechanism of a speed
governor consists of 3 basic
elements;
Sensing Transmitting Correctin
g
 Student understood that governor
must be quick to respond to
changes in the system speed, and
transmit a corrective responsive
signal to correct the error.
In case of maximum loading, the
governor should be quick to reject the
load by opening an ACB and then
control the system speed to S.N.L that is
when there is no disturbance.
In case when the governor fails to
regulate speed, electrical and
mechanical over speed devices trigger
generator shut down.
When the turbine speed reach around
205 rpm, the electrical over speed
device speed will initiate a shutdown of

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a generator.
However, when the speed reaches 305
rpm and the electrical over speed device
could not regulate the turbine speed, a
mechanical shutdown is initiated by a
mechanical over speed device.

(7-9)-11- Control room  Student had 3-day period in the  Student appreciated the tasks
2018 control room carried out in the control room
by the control room technician
and some of the tasks are
a) voltage regulation (manually
rotating control nobs to regulate
the required voltage)
b) receiving alarm
 Student completed a 2 months c) synchronising generators
period in the operations d) loading machines
department  student appreciated the overall
function of the operations
department

Supervisor’s overall comment (operations department)

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Supervisor’s Signature: ……………………………DATE…………………………...

Student Signature…………………………………

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Week Summary Activity Recommendations/ Supervisor

Lesson Learnt Sign
16-11- Electrical  Student was introduced to the electrical  Student learnt to use instruments
2018 department department senior foreman and assigned (Mega, multimeter and Tong) that were
to work with artisan necessary for carry out the maintenance
 Student took part in monthly routine procedure.
maintenance of the mulsifire air
compressors number 1 & 2.
 Student did the following during
execution of the maintenance procedure:
a) cleaned the compressors before and after
conducting maintenance procedure
b) measured line voltage,
c) exercised copper earth bars tightness
d) recorded cut in and cut out pressure and
e) current drawn by the motor on load for
both compressors 1 & 2.
Challenges faced in conducting routine
maintenance procedure
i) Student lacked familiarity with
instruments used (Mega, Multimeter and
Tong) in conducting the maintenance
procedure but later appreciated how to
use them with the help of an artisan.

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Wee Summary Activity\ Work done Recommendations\ Supervisor

k Lessons learnt
Routine  Student took part in carrying out a
22- maintenanc monthly routine maintenance of
11- e (battery battery banks 1& 2 and the tests
2018 banks) conducted were;
a) Visual inspection
Checking for electrolyte level and
topping up distilled water.
b) electrolyte composition
Hydrometer used to measure specific
gravity, a ratio of acid to water content
in the electrolyte. The measured sg value
was 1275 s.g and was falling within the
expected maximum and minimum values
of 1280s.g and 1250s.g respectively.
Precautions during testing electrolyte
Safety goggles and pvc gloves to prevent
acid burns.
Sign
 Student learnt how to use a hydrometer.
 Student also learnt that low specific gravity
value (below 1250s.g) will result in plates
becoming hydrated while if its above 1280
s.g, the plates and grids are liable to be
corroded. SG value increases during
charging and decrease during discharging.
 Student learnt that impedance test is
important to determine weakness in cells
and intercell connectors

c) Impedance test
Impedance test was done by The condition of each cell in the string (impedance,
i) applying AC test signal to the voltage and current) is measured and trended to
terminal plates. determine when to replace a cell or string which
ii) measuring total AC current in help in budgeting for replacement (impedance
the string and increases with aging of cell).
iii) voltage drop of each unit in
the string by measuring each
cell and intercell connector
consecutively until the entire
string is measured.
 Student recommends the installation of
Draft tube  Student did routine maintenance of barricades in the draft tube gallery since

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26- fan forced draft fan maintenance in the there is risky of falling from heights into
11- maintenanc draft tube gallery. The tests conducted open trench.
2018 e were  However, the draft tube gallery requires
i) Exercising bolts for tightness proper lighting always since the area is
ii) Measure current drawn on misty.
load by motor (15.5 A)
iii) Checks on motor fans and
cover for tightness
Precautions in executing maintenance
procedure
Slips, trips or falls – caution, wear safety
shoes with good grip
Falls from height – use of screens or
barricades.

Week Summary Activity / work done Recommendations/ Supervisor

Lessons learnt Sign
28-11- Earthing  Student took part in earthing of the  Student learnt that the bonding
2018 (civil civils garage fuel station by; conductor is to ensure that the potential
garage fuel making the metal enclosure of the fuel on all exposed conductive metalwork is
station) pump and a partially earthed steel rod virtually the same. (i.e. the bond
connected together via a bonding conductor equalises potential within the
conductor. site so that the resulting potential
difference are minimum)
 Student learnt other types of earthing
systems and examples are
a) TN-S (Earth neutral separated)
b) TN-C (earth neutral combined)
c) IT (isolated earth)

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Supervisor’s comment

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Supervisor’s Signature: ……………………………DATE…………………………...

Student Signature…………………………………

Wee Summary Activity/ Work done Recommendations/ Supervisor

k Lessons learnt. Sign

Replacemen  Student took part in replacing lights in the  Student learnt how to wire a
13- t control room. Activities carried out involved florescent light
12- of lights the following
2018 (Control i) Wiring florescent lights
room) ii) Mounting lights in the control room.

Supervisor
iii) Fault finding on florescent parts like  Student had familiarisation and use Sign
ballast and starter done by checking for of a multi meter.
continuity test on individual parts of the
florescent light.

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Achievements
Student could be able to wire florescent lights with
little assistant from an apprentice student.

 Student carry out a routine procedure of  Student learnt that electric arc is
19- TCW valve yearly TCW valve maintenance. The tasks formed when contacts are closed
12- routine conducted were and causes formation of carbon
2018 maintenance 1. Measuring insulation resistance using Mega on the surfaces of contacts.
multi meter.
2. Cleaning contacts inside the control panel of
the valve. Cleaning of contacts was done as  The carbon formed during
follows arcing needs cleaning as it
a) Removing arch chutes on the surface of provides a lower resistance path
contacts which reduces the power
b) Spraying the contact surfaces with brasso supplied to the activation of the
(liquid solvent) valve opening/closing. Supervisor
c) Rubbing the surfaces of contacts with cloths sign
until all the carbon and surfaces shinny.

 Student cleaned stator windings of Unit 5  Stator cleaning is done to

generator and the activities carryout were; remove contaminants that results
28- Stator 1. Spraying white spirit solvent on the surfaces in weakening winding insulation
12- cleaning of the stator (solvent takes short time to as their presence results in poor
2018 (Power vaporise) air circulation in the stator.
house) 2. Wiping down contaminants using non-linden  Student learnt that the
cloths. contaminants on the surfaces of
the stator causes damage to the
winding insulation and is a
combination of
1. Generator thrust bearing oil

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leaking into the stator surfaces

Challenges faced in cleaning stator windings
1. Restricted space to clean stator end windings
contaminants.
2. Poor posture in executing the cleaning
process
2. Dust from wearing of brake pads
during stoppage of the machine
3. Dust from slip ring carbon
brushes
Recommendations
 Student recommends or suggest
the removal of two adjacent
poles to enable easy access to
clean the rotor poles.
 Student also recommend the
design of modern equipment that
can carry out the cleaning
process to replace manual or
hand cleaning done at the power
plant.

Supervisor’s comment

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Supervisor’s Signature: ……………………………DATE…………………………...

Student Signature…………………………………

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