INDUSTRIAL ATTACHMENT REPORT

NAME: AUSTIN MASUA MUVINGIA

ADMISSION NUMBER:20263
TRAINING INSTITUTION: TAITA TAVETA NATIONAL POLYTECHNIC

COURSE: MECHATRONICS LEVEL 6

ATTACHMENT INSTITUTION: WEST KENYA SUGAR COMPANY(NAITIRI)

PERIOD: FROM 16th SEPTEMBER TO 16th DECEMBER

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DECLARATION

I hereby declare that this attachment report is my original work done

under the guidance of my technicians. This report is submitted in the
partial fulfillment of the requirements for the award of Diploma in
Mechatronics engineering.
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DEDICATION

I dedicate this work to my family, friends, TTNP electrical department

and West Kenya sugar company-Naitiri unit team as whole for being a
great motivation and willing to give me skills required during my
entire attachment period.

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ACKNOWLEDGEMENT

I would like to thank the almighty God for the gift of life and strength
throughout my attachment period. I would also thank the West
Kenya Sugar company-Naitiri unit fraternity for granting me an
opportunity to learn and gain more skills at the company. They
provided to me the best learning experience that guided me in
writing this report.

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 TABLE OF CONTENTS
DECLARATION…………………………………………………………………………………. 2
DEDICATION…………………………………………………………………………………… 3
ACKNOWLEDGEMENT…………………………………………………………………… 4

CHAPTER ONE
1.0 INTRODUCTION………………………………………………
…….………………… 7
1.1 OBJECTIVES OF THE ATTACHMENT………………………………………………
7

CHAPTER TWO
1.2 HISTORY OF ATTACHING COMPANY……………………………………………8
1.3 MISSION…………………………….…………………………………………………….8
1.4 VISION………………………………………………………………………………………8
1.5 CORE VALUES……………………….………………………………………………….9
1.6 ORGANIZATION STRUCTURE…………………………………………….…….10

CHAPTER THREE
1.7 INSRUMENTATION AND CONTROL……………………………………………12
1.8 TYPES OF GAUGES…………………….……………………….………………………
15
1.9 TYPES OF POSITIONERS…………………………………………………………….20
2.0 TYPES OF ACTUATORS………………………………………………………………25

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2.1 THERMOCAUPLES…………….…………………………………………………….26
2.2 RESISTANCE TEMPERETURE DETECTOR……………………………………27
2.3 PROGRAMMABLE LOGIC CONTROLLER……….……………………….….29
2.4 DISTRIBUTED CONTROL SYSTEMS………………………………….……….30
2.5 MOTORS…………………………………………………………………………………31
2.6 TYPES OF MOTORS USED IN INDUSTRY……………………………………32

CHAPTER FOUR
2.7 KNOWLEDGE, SKILLS AND EXPERIENCES ATTAINED……………………
38
2.8 CHALLENGES……………………………………………………………………….……38
2.9 CONCLUSION……………………………………………………………………………39
3.0 RECOMMENDATIONS………………………………………………………………39

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CHAPTER ONE

INTRODUCTION

 This chapter deals with the background of West Kenya Sugar

Company Limited. Naitiri unit purpose and objectives of
industrial attachment.

OBJECTIVES OF ATTACHMENT

 The objective of the industrial attachment is mainly to link

industry and training institution for placement of students at
the work place for acquisitions of practical skills and
appropriate work ethics before entering the labor market.

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CHAPTER TWO

HISTORY OF ATTACHING COMPANY

 The West Kenya Sugar Company Limited- Naitiri unit is in

Bungoma county, Bungoma North district at Naitiri along
Sikhendu Naitiri road. Naitiri sugar is in a land of about 50
hectares where it started setting up the machines in the year
2016 until February 2022 when it started milling sugar 3000
tons per day. Naitiri sugar mills brown sugar is sold to the local
market.

MISSION

 The mission of this industry is to create job opportunities to the

neighboring people who are skilled and to improve the
infrastructure of Naitiri area.

VISION

 The vision is for the company to emerge and become one of the
leading producers of sugar in the western region and to be a big
organization.

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CORE VALUES

 Integrity
 Honesty
 Self-disciplined

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 ORGANIZATION STRUCTURE

CHAIRMAN

MANAGER DIRECTOR

GENERAL MANAGER

PROCESS MECHANICAL ELECTRICAL CIVIL HR & ADMIN FINANCE

MANAGER MANAGER MANAGER MANAGER MANAGER MANAGER

SUPERVISOR SUPERVISOR
CIVIL
ENGINEERS

SECURITY

MANAGER
SECURITY
OPERATORS
SUPERVISOR
DRIVERS

CAPENTERS

PLUMBERS
SECURITY
CLEANERS
PERSONNEL

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CHAPTER THREE

INSTRUMENTATION AND CONTROL

 Instrumentation and control are an engineering discipline that

focuses on the design, installation, and management of systems
used to monitor, control and automate industrial processes.

Instrumentation

 Instrumentation refers to the devices and systems used to

measure physical parameters in a process. These parameters
include:
a) Temperature
b) Pressure
c) Flow
d) Level
e) pH

CONTROL

 Control involves the use of systems and strategies to regulate

processes to meet desired operational goals.

Key Elements in Control systems

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 a) Sensors
 Is a device that detects or senses a physical phenomenon
(temperature, pressure, light, motion etc.) and converts it into a
signal that can be measured or interpretated.

 Types of sensors
 Temperature sensors e.g., thermocouples, RTDs, thermistors, IR
sensors
 Pressure sensors e.g., strain gauge-based pressure sensor,
piezoelectric sensors, capacitive pressure sensors.
 Proximity sensors e.g., inductive sensors, capacitive sensors,
ultrasonic sensors.
 Motion sensors e.g., Accelerometer, gyroscopes, vibration
sensors.
 Light sensors e.g., photodiodes, LDR, photovoltaic cells.
 Force and load sensors e.g., strain gauges, piezoelectric force
sensors.
 Humidity sensors e.g., capacitive humidity sensors, resistive
humidity sensors.

b) Controllers

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  Process the sensor data and decide corrective actions.
Examples:
 Proportional Integral Derivative (PID) controllers.
 Programmable Logic Controllers (PLCs).
 Distributed Control Systems (DCS).

c) Actuators
 Execute corrective actions, e.g., motors, valves or dampers.

d) Transducers
 Is a device that converts one form of energy into another.
Specifically, it takes the output from a sensor and transforms it
into a different type of signal, such as from mechanical energy
to electrical energy.

Types of transducers
 Electrical transducers e.g., thermocouples, piezoelectric
crystals, hall effect sensors.
 Mechanical transducers e.g., bourdon tubes, diaphragms.
 Optical transducers e.g., photoresistors, optical encoders
 Pneumatic and hydraulic transducers e.g., bellows,
pressure transducers

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 GAUGES
 These are instruments used to measure temperature, pressure
of gases or liquids.
 There are many types of pressure which we are going to look at:

Types of pressure gauges

1. Bourdon Tube Pressure Gauge
 Uses a coiled tube that straightens when pressure is applied. It’s
one of the most common types, suitable for high pressure
applications.

2. Diaphragm Pressure Gauge

 Uses a flexible diaphragm that deflects under pressure, ideal for
low pressure and corrosive environments.

3. Capsule pressure Gauge

 Consists of two flexible diaphragms welded together, sensitive for
very low pressures and used for measuring gas pressure.

4. Differential pressure gauge

 Measure the difference between two pressures, often used in
filtration systems, HVAC, and fluid flow applications.

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 5. Bellows Pressure Gauge
 Uses a metal bellows that expands or contracts under pressure,
suitable for moderate pressure ranges.

6. Manometer
 A liquid column gauge that measures pressure by the height of a
liquid column, typically used for low pressure applications.

7. Digital Pressure Gauge

 Uses electronic sensors to measure pressure and display the value
digitally, providing high precision and ease of use.

8. Vacuum Pressure Gauge

 Measures pressure below atmospheric pressure, often used in
vacuum systems.

9. Hydraulic Pressure Gauge

 Designed specifically to measure high pressures in hydraulic
systems.

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POSITIONER

 Is a device commonly used in control systems, especially with

valves, to ensure accurate positioning based on the control
signal.
 Here’s is a breakdown of its key components and their
functions:

1) Input Signal Port

 Receives the control signal (commonly a 4-20 mA
current signal or pneumatic signal) from the
controller.

2) Actuator connector
 Connects the positioner to the valve actuator to
control its movement.

3) Feedback Mechanism
 Monitors the actual position of the valve (e.g., via a
cam or linkage)
And sends feedback to the positioner.

4) Control Element

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  Compares the input signal with feedback to
determine the required adjustment in the actuator.

5) Pneumatic Relay
 Converts electrical signal (if it’s an electro-pneumatic
positioner) into a pneumatic signal.

6) Supply Air Port

 Provides the compressed air needed to operate
pneumatic actuators.

7) Nozzles and Flappers

 Regulate air pressure to control the actuator’s
movement.

8) Calibration Adjusters
 Allows the technician to fine-tune the device for
precise control and proper signal interpretation.

9) Housing
 Protects the internal components from
environmental conditions like dust, moisture and
vibrations.

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 10) Display
 Provide visual feedback, such as valve position or
signal status.

Types of Positioners
 Pneumatic positioners
 Electro-Pneumatic positioners
 Digital positioners
 Smart Positioners

i. Pneumatic positioners
 Works with compressed air to control valve position.
 Has air ports, gauges and a control knob or lever.

Electro-pneumatic positioners

 Combines electrical and pneumatic signals to control the

valves.

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  Has both pneumatic and electrical connections, often includes
a display or dials.

Digital positioners
 Uses digital signals (e.g.,4-20 mA) and microprocessors to
control valve with high precision.
 Has an often box-shaped with a digital display, keypad.

Smart Positioners
 An advance type of digital poisoner with diagnostics and
wireless communications.
 Looks similar to a digital positioner, but may have additional
interfaces or indicators for data monitoring.

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 ACTUATORS
 Is a device that moves something.
 There are different types of actuators which include:

Types of Actuators

i. Pneumatic Actuators
 Uses air pressure to move the valve stem.
 Cylindrical body with air ports and often a piston or diaphragm.
 They are simple, fast and reliable.

ii. Electric Actuator

 Powered by electricity to drive the valve open or close.
 Typically, a motor attached to drive the valve with electrical
connectors, may have a housing for electronics.

iii. Hydraulic Actuator

 Uses hydraulic fluid pressure for valve movement.
 Similar to pneumatic actuators but heavier, with fluid lines and
a reservoir or accumulator.

iv. Spring Return Actuator

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  Uses a spring mechanism to return to a default position
when power is lost.
 Looks like a pneumatic or electrical actuator but
includes a spring compartment.
v. Rotary Actuator
 Provides rotational motion instead of linear, often
used for quarter turn valves.
 Compact often cylindrical or rectangular with a
rotating shaft or lever.

THERMOCOUPLES

 Works based on the see beck effect, which states that when
two dissimilar metals are joined at two junctions and exposed
to different temperatures, a voltage (thermoelectric effect EMF)
is generated proportional to the temperature difference.
 Produces a small voltage (mV) that can be correlated to the
temperature.
 Consists of two wires made of different metals joined at one
end (measuring or hot junction).

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  Typically, suitable for temperatures ranges (-200 0 C to 18000 C,
depending on the type of thermocouple).

Advantages
 Simple
 Rugged
 Suitable for high temperatures
 Rapid response

Disadvantages
 Requires reference junction compensation
 Less accurate than RTDs
 Susceptible to noise

RESISTANCE TEMPERATURE DETECTOR

Works based on the principle that the electrical resistance of a

material changes with temperature.

 Most RTDs use pure metals like platinum, which have a well-
defined, stable relationship between resistance and temperature.

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 Produces a resistance change that can be measured and
correlated to temperature using a standard calibration curve (e.g.,
pt 100 has 100 ohms at 00 C).
 Made of a thin wire (commonly platinum) wound around a
ceramic or glass core.
 Typically operates in more limited range (-200 0 C 6000 C for most
platinum RTDs).

Advantages
 Highly accurate
 Repeatable
 Stable over time

Disadvantages
 Slower response
 More expensive
 Requires an external current source for measurement.

PROGRAMMABLE LOGIC UNIT (PLC)

 Is a ruggedized computer designed for industrial
automation and control.

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  It is primarily used for discrete processes where high
speed and deterministic control is required.

Features
 Real-Time control
 Executes programs to control machinery or
processes in real time.

 Modular Design
 Comprised of CPUs, input/output (I/O)
modules and communication modules.

 Programming Languages
 Uses IEC 61131-3 languages such as Ladder
Logic, Function Block Diagram and Structured
Text.

 Fast Response
 Optimized for applications requiring quick
response times.

Applications
 Packaging systems
 Conveyor systems
 Assembly lines
 Discrete manufacturing

Advantages
 Low cost and highly customizable.
 Excellent for simple, high speed logic processes.
 Easy to program and modify.
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 Disadvantages
 Limited scalability for large, complex systems.
 Less capable of handling advanced processes control
functions.

DISTRIBUTED CONTRIOL SYSTEM (DCS)

 Is a hierarchical system designed for process automation and
control.
 It is ideal for large, continuous processes where precision and
integration are critical.

Features
1a) Centralized Monitoring with Distributed Control
 Combines centralized data collection with
decentralized control via controllers at multiple
locations.

1b) Integration
 Offers seamless integration of hardware and
software for process control, data logging and
reporting.

1c) Advanced Control

 Capable of handling complex control algorithms,
batch processing and recipe management.

1d) Homan Machine Interface (HMI)

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  Provides operators with graphical visualization of the
entire process.

Advantages
 Highly scalable for large systems.
 Superior data handling and visualization.
 Redundancy and reliability for mission critical operations.

Limitations
 Higher initial cost compared to PLCs.
 More complex to configure and maintain.

MOTORS
 A motor is an electrical device that converts electrical energy to
mechanical energy.

Components of a motor
Function of parts of a motor

 Fan- cools the motor.

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  Stator- provides the magnetic field that drives the rotating
armature.
 Rotor- it’s the rotating part of a motor which is attached to the
shaft
 Shaft- it spines with the rotor creating ac current.
 Windings- are insulated wires around the magnetic core which
provides path for electrical current flow.
 Bearings- to reduce friction and smoother rotation.
 Fan cover- protects the motor against mechanical damage

Types of Motors used in the company (AC)

 Induction motors which include squirrel cage and slip ring
induction motors.
Differences between squirrel cage and slip ring induction
motors

Squirrel cage induction motor Slip ring induction motor

Low starting toque High starting toque

Efficient is high Efficient is low
Construction is simple Construction is complicated
because of slip ring and brushes
No external resistance circuit as External resistance circuit is
bars and rotors is completely
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 slotted connected with the rotor

Applications of slip ring induction motors

 These motors are used where high torque and low current are
required like cranes, elevators, conveyors, hoist, shredder, HOC
and chopper.

Applications of squirrel cage induction motors

 These are used in centrifugal pumps, fans, large blowers, run
conveyor belt etc.
 NB; External resistance acts as a variable rheostat during the
motor kick off and tweaks automatically to high resistance to get
required starting current.

Methods of starting motor

 Direct Online Starter (DOL)
 Star Delta starter
 Forward and reverse/Reverse direct online starter
 Variable frequency drive starter

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Direct online starter (DOL) Power and control unit

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Star Delta starter power and control circuit

Forward and reverse/Reverse direct online starter power and control

circuit

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Variable frequency drive (VFD)
 These are electronic devices that manipulate electrical current to
electric motors to control speed and torque.
 They are used in industries to funnel AC power, convert it into DC
power and temporarily store converted current until it is needed.
 VFDs in insulated gate bipolar transistors allow rapid modulation
of incoming and outgoing current.
 They reduce the time and resources needed to perform operation,
increase safety of equipment reduce electric costs and extend life
of motor.

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 CHAPTER FOUR
Knowledge, skills and experienced attained
 Able to service a pressure and temperature gauges.
 Able to do data analysis.
 Install AC and DC machines
 Interpreted technical drawings

Challenges
 My training experience has been quite good, though I faced
some challenges before I progressed with my training
although they did not bring me down.
 Some of the challenges include:
a. Final problem- during the period of looking a place to
be attached it required money for travelling cost to
deliver attachment request.
b. Inadequate housing facilities- It was difficult to secure
a place around the company to settle although I got a
place to settle.
c. Inadequate transport facilities- walking from long
distance was difficult to the attached place for daily
work activities.

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 Recommendation
 To promote the quality of training, the administration
should start making partnership with companies.
 Most students have struggled looking for companies which
has hosted them during the attachment period that is why
TTNP should look into companies which will host students.

Conclusion
 The attachment at West Kenya Sugar Company was
successful.
 I was able to do more practical about power
generation and distribution in the company. I
acquired more skills on electrical.

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