INDUSTRIAL ATTACHMENT REPORT

NAME: BONVENTURE OTIENO

ADM NO.: 17812

TRAINING INSTITUITION: COAST INSTITUE OF TECHNOLOGY

COURSE: MECHANICAL ENGINEERING (PLANT OPTION)

ATTACHMENT INSTITUITION: SOUTH NYANZA SUGAR COMPANY LIMITED

ATTACHMENT PERIOD: 3MONTHS

FROM: 04/09/2023 TO 30/11/2023

NAME OF SUPERVISOR: ENG. AKONDO

 DECLARATION
I Bonventure Otieno hereby declare that this industrial attachment report is my own original work
and has never been submitted before for any academic award either in this firm or any other
institution of work or higher learning for academic publication or any other purpose. Within is a
detailed description entailing all the activities that I undertook during my 3-month attachment
period at the firm.

APPROVAL

Sign…………………………………… Date…………………………………

Confirmed by supervisor

Sign………………………………….. Date………………………………..
ACKNOWLEGDEMENTS
My appreciations go mostly to God for the unending guidance in the right direction and
protection coupled up with wisdom for every day. I cannot also take for granted the opportunity
that the firm gave me to accomplish part of my academic requirement, the care and concern I got
from the employees not only aimed towards educating me but also to care for my personal
wellbeing,. I will forever be indebted to them all.
TABLE OF CONTENTS
DECLARATION....................................................................................................................2
ACKNOWLEGDEMENTS....................................................................................................3
TABLE OF CONTENTS........................................................................................................4
CHAPTER ONE.....................................................................................................................6
1.2 ABSTRACT......................................................................................................................6
1.3 OBJECTIVES OF ATTACHMENT................................................................................6
CHAPTER TWO....................................................................................................................7
2.2 HISTORY OF ORGANIZATION....................................................................................7
2.3 MISSION..........................................................................................................................7
2.4 VISION.............................................................................................................................7
2.5 CORE VALUES...............................................................................................................7
2.6 ORGANIZING STRUCTURE.........................................................................................8
CHAPTER THREE................................................................................................................9
3.1 GENERAL ATTACHEMENT ACTIVITIES..................................................................9
Detailed Description of Daily Activities.................................................................................9
3.2 PRE-MILLS......................................................................................................................9
3.2.1 Weigh bridge..................................................................................................................9
3.2.2 Hydro unloader..............................................................................................................9
3.2.3 Overhead cranes/Gantt.................................................................................................10
3.3 MILL SECTION.............................................................................................................10
3.3.1 Fiber-Rake Carrier.......................................................................................................10
3.3.2 Types of rollers............................................................................................................10
a) Top roller.....................................................................................................................10
b) Feed roller...................................................................................................................11
c) Underfeed roller..........................................................................................................11
3.3.3 Types of mills..............................................................................................................11
3.3.4 Mill Drive Mechanism.................................................................................................11
3.3.5 Power transmission systems........................................................................................11
Gears.....................................................................................................................................11
Advantages............................................................................................................................12
Types of gears.......................................................................................................................12
3.3.6 Couplings.....................................................................................................................12
Types of Couplings...............................................................................................................13
3.3.7 Bearings.......................................................................................................................13
Types of thrust bearings........................................................................................................13
Components of a bearing rolling contact bearings...............................................................14
3.3.8 Pumps...........................................................................................................................14
Type of centrifugal pumps................................................................................................14
Components of centrifugal pump.........................................................................................15
3.3.9 Valves..........................................................................................................................15
3.3.10 Lubrication systems...................................................................................................16
3.4 WORKSHOP..................................................................................................................17
3.4.1 Lathe machine..............................................................................................................17
3.4.2 Drilling machine..........................................................................................................17
3.4.3. Milling machine..........................................................................................................17
3.4.4 Welding........................................................................................................................18
3.4.5 Weld defects................................................................................................................18
3.5 PROCESS SECTION.....................................................................................................19
3.6 JUICE HEATING...........................................................................................................19
3.6.1 Evaporators..................................................................................................................19
3.6.2 The Clarifier.................................................................................................................19
3.6.3 Rotary Vacuum Filter..................................................................................................19
3.6.4 Vacuum creation zone..................................................................................................19
3.6.5 Crystallization of Juice................................................................................................20
3.6.6 Drier barrel and drive system.......................................................................................20
3.6.7 Grading, storage and bagging of the sugar crystals.....................................................20
3.7 BOILER SECTION........................................................................................................21
3.7.1 Air systems..................................................................................................................21
3.7.2 Water System...............................................................................................................21
3.7.3 Flue Gas System..........................................................................................................21
3.7.4 Steam System...............................................................................................................21
3.7.5 Ash System..................................................................................................................22
3.7.6 Maintenance of the Boiler............................................................................................22
CHAPTER FOUR.................................................................................................................23
4.1 SKILLS AND EXPERIENCES......................................................................................23
 4.2 CHALLENGES..............................................................................................................23
4.3 CONCLUSION...............................................................................................................23
4.4 RECOMMENDATION..................................................................................................23

CHAPTER ONE

1.1 INTRODUCTION

This is analysis report of South Nyanza Sugar Company during my attachment at the manufacturing
department. The report comprise of activities undertaken at the Manufacturing department and a brief
summary of the mission, vision and the core values of the company.

Sony sugar is located in Migori County. The company also has offices in Nairobi for liaison purposes and for
a availing it’s products and services closer to it’s customers.

Sony sugar serves over 30,0000 farmers spread in seven districts of Rongo,Migori, Homa
Bay,Gucha,Uriri,Kuria and transmara.

1.2 ABSTRACT

This report is a technical summary of my experience at South Nyanza Sugar Company Limited.
Within is the description of sections that I was allocated to, the skills I gained as far as machine
operation and maintenance is concerned. The field experience was indeed relevant and important as it
allowed me to acquire a physical perspective of most of the things I learnt in class and apply myown
knowledge for the betterment of the firm.

1.3 OBJECTIVES OF ATTACHMENT

1. Apply skills leant in class onto the field like teamwork, safety and use of some tools
2. Acquire more knowledge cornering my academics and in other
sectors such as social and cultural
3. Get an opportunity to use different machines.
 CHAPTER TWO
2.2 HISTORY OF ORGANIZATION

It was established in 1976 under the companies Act Cap 486 of the laws of Kenya and
commissioned in 1979. The company premise and sugarcane nucleus estate sit on an area covering
2492 hectares without-growers cane area of 15500 hectares. The company serves over 25,000 cane
farmers in ten districts within the cane growing zone at Homabay, Gucha, Trans Mara, Kuria Migori,
Uriri, Rongo, Kisii south Ndhiwa and AwendoThe company contribute significantly to the
realization of Kenya’s vision 2030 through sugar production whose current capacity stands at 2500
TCD.Government is the main stakeholder of the company owing 98.8%, centum investment co.
(ICDC) 0.717%, industrial development bank (IDB) 0.28% and Mehta group 0.21%.The company is
managed by the MD assisted by the managers of different departments for example : factory
manager, agriculture manager, human resource manager ,finance manager and marketing manager.

2.3 MISSION

Sustainable production of sugarcane, manufacture and market of quality and associated products of
the delight of customer.

2.4 VISION

To be a leading world class manufacturer of preferred sugar and associated production.

2.5 CORE VALUES

Customer first
Integrity
Sustainability
Professionalism
Entrepreneurship
Safety
Timeliness
2.6 ORGANIZING STRUCTURE
 CHAPTER THREE

3.1 GENERAL ATTACHEMENT ACTIVITIES

Detailed Description of Daily Activities

During the 3 month stay we were assigned to three major sections for each month and
they included the pre-mills and mills section, process section and boiler section.
During our free time we would be taken around to see other smaller yet equally
important sections such as water treatment plant (WTP) and effluent treatment plant
(ETP).
3.2 PRE-MILLS

The process of extracting the sucrose buried deep in the sugar cane and converting it
into sugar crystals begins at the Cane Yard. Knives, where it is cut to pieces.

3.2.1 Weigh bridge

 The main function of Weigh Bridge is to weigh the entire truck’s load of goods in
industries where the material can be weighed only at the time of movement from one
place to another.
3.2.2 Hydro unloader
 Offloads cane from the tracks into the cane yard
 It has the ram that clamps the truck against the wall during offloading

 It has wheels that move along the foundation for flexible offloading.
  Offloads cane from trucks directly onto the feed table.

 It was the hydraulic power pack system for operation

 It uses the hydraulic power pack (discussed below) for operation.

3.2.3 Overhead cranes/Gantt

Offloads cane from the truck into the cane yard. It also loads cane on the feed table. It
uses the hydraulic power pack system for operation and the crane wheels move along
the cane rails.

3.3 MILL SECTION

Flow of crushed fiber across the Mill Section

3.3.1 Fiber-Rake Carrier

Receives prepared cane from the fibrizor and delivers it to the fiber carrier conveyor. It’s a
slat
rake chain conveyor and inclined towards the fiber carrier conveyor.

3.3.2 Types of rollers

They have four rollers each that squeeze the juice from the crushed fiber. The rollers include;
a) Top roller
It’s the drive roller for the three rollers and allows for fiber delivery into the other
rollers, pinions are fitted onto both ends of the shaft .The pinions’ teeth mesh with
those of the other rollers thus are driven. It uses the hydraulic power pack system
 with nine pneumatic accumulators for pressure application and adjustments during
milling.
b) Feed roller
Parallel to but slightly below the top roller. It delivers fiber to the underfeed roller.
c) Underfeed roller
Provides a surface for fiber squeezing .It also delivers fiber to the discharge roller Discharge
roller
It delivers squeezed fiber to the inter-carriers rake elevator.

3.3.3 Types of mills

 Pressure mill ( the one used in the firm)
 TRPF mill
 GRPF mill

3.3.4 Mill Drive Mechanism

The mills are driven by;

i. Motor drives
ii. Turbine drives

It’s powered by a motor that’s coupled (gear coupling) to the planetary gearbox that
reduces speed and increases torque. The top roller is coupled via a rope coupling.
Rope coupling is suitable due to varied adjustments on the ropes, the ropes tighten
and slacken prevent breakage.

3.3.5 Power transmission systems

Gears
The primary function of the gears in this section is to
 i. Reduce speed
ii. Increase torque
iii. Change direction
 To reduce speed, a gear with fewer teeth is connected to a larger gear with
more teeth. The smaller gear makes more revolutions as compared to the
larger gear, thus power output is less compared to power input.
 Speed is reduced so as to increase torque ( the force that acts in a circular manner)
 Change in direction is achieved when the driver gear moves clockwise then
the follower gear moves anti clockwise and vice versa.
Advantages
 Constant energy transmission, no slipping
 Ideal system for very high rotational speeds
Disadvantages
 Can generate noise and vibration
 Require lubrication
 Sensitive to impurities
 Require precise adjustments
 Manufacturing gears requires precision machines,
which make them a bit more expensive

Types of gears

 Helical

 Herringbone (double helical)

 Planetary (Epicyclic)

 Pinion and Rack

 Bevel

3.3.6 Couplings
  They include rope coupling and gear coupling
Types of Couplings

3.3.7 Bearings
Types of Bearings
They are used to support moving machine elements such as shafts. It permits relative motion
between the contact surfaces, while carrying the load thus reducing friction between moving parts
Classification of bearings are classified

Based on the direction of the load:

 Radial bearing- Load acting perpendicular to the direction of motion of moving
element (withstands radial load)
 Thrust bearings- Load acts along the axis of rotation (axial load)

Types of thrust bearings

 Journal/ Sliding contact bearing- Sliding takes place between the fixed and the moving
 element of the bearing.
 Rolling contact bearing- Balls or rollers are introduced between moving and fixed elements
Components of a bearing rolling contact bearings

Outer ring
Inner ring
Ball retainer
Inner ring ball race
Shoulders

Types of rollers used in Rolling contact bearings

The type of roller used determines the load capacity of the bearing. The more the contact area the
more the load capacity and hence more friction

Ball
Spherical roller (Symmetrical/ Asymmetrical)
Cylindrical roller
Needle roller
Taper roller
 Combined load bearing- Load acts in both perpendicular and along the axis of rotation
of the bearing.
3.3.8 Pumps
Types of pumps
 Positive displacement

They reduce volume of liquid so as to reduce pressure. They are connected in motor- gear- pump
order
Types of positive displacement pumps
 Rotary
 Reciprocating
 Centrifugal pumps

They increase kinetic energy of the liquid they are connected directly to the motor
 Type of centrifugal pumps
 Horizontal
 Vertical
 Single stage
 Multi stage
Components of centrifugal pump
i. Shaft
Is a mechanical component for transmitting torque from motor to impeller.
ii. Impeller
It physically moves the liquid through the pump. It is a rotor used to
increase kinetic energy of low of liquid
iii. Bearings
Constrains the relative motion of the shaft
iv. Casing/ Volute
Acts as a pressure containment vessel, that directs liquid in and out of the pump
v. Gland following
vi. Sleeve

vii. Shifting box

viii. Lock nut
Used to ensure there are no oil leakages
ix. Gland packing
They are ropes cut and placed inside the pump to prevent leakages and also help reduce
friction
x. Shaft sealing

3.3.9 Valves
They are devices that regulate, direct or controls flow of a liquid by opening and closing
passageways
They include;
  Butterfly valve
 Needle valves
 Safety and relief valves
They rapidly opens as the pressure setting is reached and will stay open until the pressure of
liquid flowing system drops lower than the set maximum pressure point.

Both valves are used to prevent damages by relieving accidental over-pressurized fluidsystem
 Control valve
 Gate valve
Classified depending on the type of disk used
i. Solid wedge
ii. Flexible wedge
iii. Split wedge
iv. Parallel disk
 Ball valve
The valve uses a ball shaped disk with a hole in it. When the valve is open, the hole ofthe disk
is turned in line with the direction of the flow
 Diaphragm valve
 Check valve(non -return valve)
They prevent reversal flow of liquid in the piping system. The pressure of the liquid flowing
opens the system while the weight of the liquid that has flowed passed closesthe system
 3-way valve
 Globe valve

There are three designs for the globe valve

i. Z-Body
ii. Y-Body
iii. Angle body
 Relief valve
3.3.10 Lubrication systems
Lubrication was carried out by coating moving parts with either oil or greese. It was carried out
so as to reduce friction between the parts that would otherwise cause heating and wear off the
part.
3.4 WORKSHOP

The workshop deals majorly with the production of spares required for various components
within the plant.
Machining section
Machining is the most important of the manufacturing process. Machining can be defined as the
process of removing material from a work piece in the form of chips.
3.4.1 Lathe machine
The main function of a lathe is to remove metal from a piece of work to give it the required shape
and size.

-Bed
-Headstock
-Tail stock
-Carriage assembly

Operations carried out on the lathe machine:

Facing
Drilling
Boring

3.4.2 Drilling machine

Drilling this is the operation of making a circular hole by removing a volume of metal from the
job by a rotating cutting tool called drill. Drilling removes solid metal from the job to produce a
circular hole.

 Reaming
 Boring
 Counter-boring
 Lapping
 Spot-Facing
3.4.3. Milling machine
Milling may be defined as a machining operation for removing excess material from a work
piece with a multi-tooth rotating cutter. Flat or curved surfaces of many shapes can be machined
by milling with good finish and accuracy.

3.4.4 Welding
In electrode welding, contact between the rod electrode and work piece ignites the arc. This
creates a short circuit for a fraction of a second between the two poles, meaning that current can
then flow.
ADVANTAGES DISADVANTAGES
Easy handling Low welding speed
Almost all metallic materials can be Increased error sources due to end-craters and
welded contact
positions
Easy to learn Lots of smoke is produced
Low noise Occurrence of arc blow

3.4.5 Weld defects

 Weld Crack

 Undercut

 Spatter
 Porosity

 Overlap
  Crater

3.5 PROCESS SECTION

The juice extracted from the crushed fiber in the mills section is taken to mixed juice tank the
first procedure that the juice undergoes is heating.

3.6 JUICE HEATING

This is conducted to preheat the juice.
3.6.1 Evaporators
There are 5 evaporator bodies. -Temperature is steadily reduced from the first body
consecutively to the final body. -Vacuum is provided in bodies 4 & 5 that draws juice from one
body to the next.
3.6.2 The Clarifier
It has the center shaft that’s driven by the worm gear. The shaft has arms that stir the juice
during rotation. Stirring aids to separate mud particles with juice through sedimentation -Mud
settles in the mud booth while juice settles on top.
3.6.3 Rotary Vacuum Filter
Receives mud mixed with fine bagasse particles for juice extraction and mud disposal.

3.6.4 Vacuum creation zone

-Vacuum is created within the Barometric Condenser. Expanded vapor from the pan comes in
through the top while water is injected in spray form sideways.

Vacuum Maintenance -Vacuum is applied by cold water supply to the barometric condenser
while it’s broken by cold water supply cut-off

3.6.5 Crystallization of Juice

Crystallization occurs at the pan bodies. Syrup from evaporator body 5 is pumped into the syrup
receiver tanks where it mixes with molasses to form massecuite. For crystals to be formed, the
following are required;
 Steam
 Vacuum
 Pressure
 Temperature

Once the crystals are formed, they undergo drying in the drier barrel
3.6.6 Drier barrel and drive system
The barrel is cylindrical and installed horizontally. -It has a center ring with teeth on its
circumference that is linked to the drive by chains.
3.6.7 Grading, storage and bagging of the sugar crystals
The 2nd bucket elevator conveys the sugar the grader. -The grader has 3 sieves that separate
standard sugar particles from big and fine sugar particles.
 3.7 BOILER SECTION
PART FUNCTION
Steam drums separate steam from water
Mud drums separate sediments from water
Boiler Generates steam
Turbines Generate electricity
Dampers Mechanically control amount of air in boiler
Super heaters Dries the steam so as to not corrode the turbine
Economizer Heats water
Air pre heaters(A.P.H) Heats air

The boiler is made up of systems that enable the boiler to perform its function, they include;
 Fuel system
 Air system
 Water system
 Steam system
 Flue gas system
 Ash System
3.7.1 Air systems
There are fans that are used to drive air. They include;
PART FUNCTION
Primary air fan Determines amount of fuel
burnt
Secondary air fan Determines efficiency of the
burnt fuel
Induced and Forced Draught fans Determines flow of flue gas

3.7.2 Water System

3.7.3 Flue Gas System

 Economizer Air pre heater
 Electrostatic precipitator

3.7.4 Steam System

 The steam produced is used to run turbines that produce electricity and the
 remaining steam is redirected to the process section where it is used to heat the juice
3.7.5 Ash System
 Submerged ash belt conveyor is used to remove the ash

3.7.6 Maintenance of the Boiler

Different parts of the boiler require regular maintenance activities

PART FAULTS AND MAINTANACE ACTIVITIES REQUIRED

Boiler conveyors -Check the oil level of the gearbox. If below the gauge top up
-Drain impure oil and refill with clean oil
-Tighten loose foundation bolts of the prime mover.
-Check the nature of the chain, if worn out, replace with new one.
– Replace worn out runners
-Check the sprocket condition. If its condition is beyond repair replace
Bagasse -Lubricate the rollers.
conveyer(1, 2,& -Replace worn out /broken bearings with new ones.
3) -Tension sagging belts.
-Repair cut belts.
-Lubricate the drum bearings.
-Tighten loose foundation bolts to avoid vibration
Pumps -Leakages (could be due to worn out gaskets, gland packing or
loose gland follower hence should be replaced
-Overheating(could be due to worn out bearings, replace with new
ones or oil level below the gauge, top up with recommended oil or
dirty oil; drain, flush and top up with new oil or dissimilar pump shaft
and motor shaft rotation direction. If running in reverse then correct.
-Vibration (misalignment with the motor, align it or lose foundation bolt,
Tighten them or loose joining units, tightly fit them.
Boiler air -Hard face the wings.
supply -Open the dumpers.
fans. -Inspect the fan through the manhole.
-Lubricate the bearing
 CHAPTER FOUR

4.1 SKILLS AND EXPERIENCES

Skills and experiences learnt include;
Routine and annual maintenance of a plant, alignment of different motors and pumps, various
functions of different valves, boiler operations, water systems, process section, pre – mill
activities.
4.2 CHALLENGES
 Trainers did not speak fluent English which caused poor communication and
in some instances difficulty in conducting duties
 Some tools such as spanners where either few or missing making it harder to do
work
 Spending a lot of time walking from and to work during lunch breaks
 Bad weather that would sometimes limit us from working outside thus
slowing down work rate.
 Insecurity

4.3 CONCLUSION
The experience was very unique, involved with its own challenges and new
opportunities. I got a chance to apply the knowledge I had acquired from school into
the field. I got enlightened with the new machinery which I was able to get a chance
to operate, finally the attachment period offered an opportunity to socialize with other
people from different walks of life and share ideas both educational.

4.4 RECOMMENDATION
 Provision of meals that can be bought thus employees and trainees do not
have to waste a lot of time walking home and back.
 Purchase of more tools that would enable work to be completed on time.