ALEX EKWUEME FEDERAL UNIVERSITY

NDUFU ALIKE
 STUDENTS’ INDUSTRIAL WORK EXPERIENCE SCHEME (SIWES)

A REPORT OF SIX (6) MONTHS INDUSTRIAL WORK EXPERIENCE

AT

THE NIGERIAN BOTTLING COMPANY PLC

(A member of Coca-Cola Hellenic group)

PLOT 326 INDUSTRIAL LAYOUT OWERRI, IMO STATE.

BY

AREH CHARLES CHUKWUEMEKA

2017/EN/5083

DEPARTMENT OF CHEMICAL ENGINEERING

FACULTY OF ENGINEERING AND TECHNOLOGY

ALEX EKWUEME FEDERAL UNIVERSITY NDUFU ALIKE

FET 490

IN PARTIAL FULFILLMENT OF THE REQUIREMENTS FOR THE AWARD OF

BACHELOR OF ENGINEERING (B.Eng.) DEGREE IN CHEMICAL
ENGINEERING

8TH FEBRUARY, 2022.

SUPERVISED BY ENGR. ALPHEUS OKAHU

ii
 DEDICATION

To my superhero mom

iii
 ACKNOWLEDGEMENT

First, I acknowledge God the source of all inspiration for this work. Also, I acknowledge my
superhero, my mother - Mrs. Florence Areh - for her selfless sacrifice in making sure I never
lacked for the entire duration of my I.T period. I also acknowledge my lovely uncle, Hon.
Azubuike Udo for helping me secure a placement in a reputable company. Thank you uncle
for being there always for us.
Next I want to acknowledge the efforts of my industry based supervisor, Engr. Lawrence Nze
for taking out much time to teach and encourage me, and to all the utility technicians of NBC
Owerri who took me as one of theirs and taught me all I needed to know within the short
period. Also, to my pal, Godwin who always stuck with me and taught me like a brother.

My special thanks goes to the plant manager - Mr. Olisa Araka, an uncle and mentor who
became a second father to me and granted me the wonderful opportunity of staying for six
wonderful months with them learning their processes and all.

Also to my SIWES coordinator and supervisor, Engr. Alpheus Okahu for his patience and
dedication in going through this work, polishing it and correcting all the mistakes therein.

Much love also goes to my lovely siblings – Nchee, Oby, Nkem and Chizoo for doing all the
work in the house thus giving me time to concentrate on this report. And to my elder sister,
Nwanne and her wonderful husband for their financial support now and then. You guys are
the best.

I cannot forget my pastor, Pst. Regis Ojiakor and his assistant, Pst. Solomon Kalu for all their
tireless effort in helping me to secure a good accommodation in Owerri town. I love you sirs’

Lastly, I want to thank everybody who in one way or the other contributed in any way to my
internship and this report and who because of omission I did not mention. You guys are all
wonderful and I remain grateful for your help. God bless you all.

iv
 CERTIFICATION

This is to certify that AREH CHARLES CHUKWUEMEKA with matriculation number

2017/EN/5083 is the bona fide owner of this technical report on the Nigerian Bottling
Company, Owerri from 17th August, 2021 to 21st January, 2022 in partial fulfillment of his
Bachelor of Engineering Programme in Chemical Engineering in the Alex Ekwueme Federal
University Ndufu Alike.

Areh Charles Chukwuemeka ______________________ _______________

2017/EN/5083 Signature Date

Engr. Alpheus Okahu ______________________ _______________

SIWES Coordinator Signature Date

Engr. Dr. C.S. Ume ______________________ _______________

HOD Chemical Engineering Signature Date

v
 TABLE OF CONTENTS

COVER PAGE
TITLE PAGE i
DECLARATION ii
DEDICATION iii
ACKNOWLEDGEMENT iv
CERTIFICATION v
TABLE OF CONTENTS vi -viii
ABSTRACT vii

CHAPTER ONE

1.0 INTRODUCTION 1

1.1 SIWES OVERVIEW 1

1.1.1 HISTORY OF SIWES 1

1.1.2 OBJECTIVES OF INDUSTRIAL ATTACHMENT 1-2

1.2 THE COCA-COLA COMPANY 2

1.2.1 BRIEF HISTORY OF THE ESTABLISHMENT 2-4

1.2.2 PLANT ORGANOGRAM 5

CHAPTER TWO

2.0 OVERVIEW OF THE COMPANY 6

2.1 VARIOUS DEPARTMENTS IN THE ESTABLISHMENT

ANDTHEIR FUNCTIONS 6

2.1.1 HUMAN RESOURCES (H.R) DEPARTMENT 6

2.1.2 QUALITY ASSURANCE DEPRTMENT 6-7

2.1.2.1 FOOD SAFETY UNIT 7

2.1.3 PLANT SAFETY DEPARTMENT 7-8

2.1.3.1 ENVIONMENTAL SAFETY PRACTICES 8

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2.1.4 SECURITY DEPARTMENT 9 - 10

2.1.5 COMMERCIAL DEPARTMENT 10

2.1.6 MANUFACTURING DEPARTMENT 10

2.1.6.1 LINE 3 10

2.1.6.2 LINE 5 10

2.1.6.3 LINE 6 10

2.1.6.4 LINE 7 11

2.1.6.5 MACHINES USED BY THE DEPARTMENT 11

2.1.6.6 PRODUCTS FROM THE MANUFACTURING DEPARTMENT 12

2.1.7 TRANSPORT DEPARTMENT 12

2.1.8 MAINTENANCE DEPARTMENT 12 - 13

2.1.9 UTILITY DEPARTMENT 13

2.1.9.1 THE WATER TREATMENT PLANT 13

2.1.9.1.1 SOURCES OF WATER 13 - 14

2.1.9.1.2 WHY TREAT WATER 14

2.1.9.1.3 WATER IMPURITIES 14

2.1.9.1.4 STAGES OF STANDARD CHEMICAL PROCESS 14

2.1.9.1.5 NBC WATER TREATMENT PROCESS 14 - 15

2.1.9.1.6 TEST POINTS 16

2.1.9.1.7 STANDARD RESULT OF NBC TREATED WATER 18

2.1.9.2 THE EFLUENT TREATMENT PLANT 18

2.1.9.2.1 TYPES OF DRAINAGES 19

2.1.9.2.2 NBC EFFLUENT TREATMENT PROCESS 19 - 21

2.9.1.3 INDUSTRIAL REFRIGERATION 23

2.9.1.3.1 REASONS FOR INDUSTRIAL REFRIGERATION IN NBC 23

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2.9.1.3.2 MACHINERY, EQUIPMENT AND SUBSTANCES

INVOLVED 23 - 24

2.9.1.3.3 WORKING PINCIPLE – THE REFRIGRATION CYCLE 27

2.9.1.4 INDUSTRIAL STEAM GENERATION 32

2.9.1.4.1 WASTE HEAT RECOVERY SYSTEM –WHRS 32

2.9.1.4.2 WASTE HEAT CALCULATION FORMULA 33

2.9.1.4.3 WASTE HEAT BOILER 33

2.9.1.4.4 APPLICATIONS OF STEAM IN NBC 34

CHAPTER THREE

3.0 SUMMARY OF MY DAILY ACTIVITIES IN THE COMPANY 35 - 36

3.1 TEST FOR GLYCOL USING A REFRACTOMTER 36

3.2 TEST FOR AMMONIA LEAKAGE DETECTION 37

3.3 BOILER BLOW-DOWN PROCEDURES 37

3.4 STEPS TO SERVICE AN AIR CONDITIONING UNIT 37 – 38

CHAPTER FOUR

4.0 CONCLUSION AND RECOMMENDATIONS 39

4.1 CONCLUSION 39

4.1.1 CHALLENGES ENCOUNTERED 39

4.2 RECOMMENDATIONS 40

4.2.1 ON PART OF THE GOVERNEMNT 40

4.2.2 ON PART OF THE SCHOOL MANAGEMENT 40

4.2.3 ON PART OF THE STUDENT 40

REFERENCES 41

viii
 ABSTRACT
This technical report covers my industrial training at the Nigerian Bottling Company Ltd,
Owerri Imo state for the duration of 23 weeks. The work highlights the practical exposure
and experience I acquired at the utility section of the plant ranging from the operation of
machines such as steam boilers, compressors; Heating, Ventilation and Air Conditioning
(HVAC) systems; Heat exchangers, pumps, valves and condensers. It also covers some
industrial processes such as water treatment, effluent treatment of wastewater, Ammonia
refrigeration, steam generation, industrial cooling. The work which is separated into three
chapters discusses the overview, aims and objectives of SIWES in the first chapter together
with the history of the establishment. The Nigerian Bottling Company Ltd employs the use of
world class machineries and standardized Coca-Cola processes and hence the second chapter
of this report x-raysthe plant overview as well as the instrumentations and process controls.
The third and final chapter consider the summary of my daily activities at the plant together
with the various tests I conducted at the utility department during my stay and the procedures
I took to achieve them. Results obtained are also included where they are required. Also in
the third chapter, I gave the steps for some other works like carried out. At the end of the
work, there was a brief conclusion of my stay at the Nigerian Bottling Company, Owerri as
well as recommendations I suggested to make the internship experience a better one.

ix
 CHAPTER ONE

1.0 INTRODUCTION

1.1 SIWES OVERVIEW

1.1.1 HISTORY OF SIWES

The students industrial work experience scheme (SIWES) was established by Industrial
Training Fund (ITF) in 1973 to solve the problems of lack of adequate practical skill and
preparation for employment by Nigerian graduates of tertiary institutions.

It was designed to give Nigerian students studying occupational related courses in the various
institutions the experience that would supplement their theoretical learning.

The scheme exposes students to industrial based skills necessary for a smooth transaction
from the classroom to the world of practicals. It is also aimed at bridging the gap between the
student’s existing theoretical knowledge and practical field experience through attachment to
industrial establishments.

The scheme afford students of tertiary institution the opportunity of being familiarized and
exposed to the needed experience in handling machinery and equipment which may not be
usually available in various institution.

The Students Industrial Work Experience Scheme is the accepted skills training program
which form parts of the approved minimum academic standards in the various degree
programs for all Nigerian universities in accordance with the education of Nigeria. It is
funded by the Federal Government of Nigeria and jointly coordinated by Industrial Training
Fund (ITF) and the National University Commission (NUC).(Nzame, 2010)

1.1.2 OBJECTIVES OF INDUSTRIAL ATTACHMENT:

The objectives of industrial attachment are:

 To prepare students for the work situation they are likely to meet after graduation.
 To afford students an opportunity to develop entrepreneurial skill and knowledge

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 To give students an opportunity to test their theoretical tools and construct, learnt
during their first three/four years of the program with the realities of running
organization as related to course of study.
 To expose Nigerian students to the behaviour of organizations, both in internal and
external environments.
 To seek industrial evaluation in our degree program in terms of relevant to industry
and commerce.
 To create partnership between the University and the private as well as public sector
enterprises.

1.2 THE COLA-COLA COMPANY

1.2.1 BRIEF HISTORY OF THE ESTABLISHMENT:

In May 8th 1886,a pharmacist Dr. John Pemberton invented the now famous Coca-Cola
formula in Atlanta, Georgia USA in a brass pot in his backyard. The name Coca-Cola was
selected by Frank M. Robinson a close partner to Dr. John Pemberton and according to him,
the two C’s would look well in advertisement along with the well-guarded formula for Coca-
Cola locked in an Atlanta bank vault which makes coke trademark to be among the
company’s most valuable assets. The stylish Coca-Cola script was also panned by Frank M.
Robinson. Studies show that the red and white Coca-Cola logo is among the most admired
and best-known trademark recognized by more than 90 percent of the world population.
(Coca-Cola Achieves, 2019)

The strong venerable contour glass of Coca-Cola bottle was created in 1915 as the company
sought to distinguish its packaging and to discourage copycats. It was designed to be
recognized even if grasped in the dark. The bottle’s “hobble skirt” outline has often been
called the world’s second most familiar shape behind the egg.

In the early 1960’s, Coca-Cola company entered a new era with the launch of Fanta, Sprite
and low-calorie Tab, plus the addition of minute maid juices and fruit drinks through a
merger with the Minute Maid Company and it was the first time the company sold any drinks
other than Coca-Cola and set the stage for an incredible expansion of products around the
world.

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The company now markets four of the world’s top five soft drink brands which are, Coca-
Cola, diet coke, Fanta and Sprite but it has a family of product that includes more than 230
different brands of drinks including juices and Eva bottled water. One hundred and thirty-six
years later, more than a billion serving of Coca-Cola company product are consumed
everyday making it today not just the most widely available consumer product sold in hearty
200 countries but also the most recognized world on the planet that generates its own power
and is self-sufficient in carbon-dioxide production.

However, The Nigerian Bottling Company (NBC) Ltd,also known as Coca-Cola Nigeria is
the bottling partner of The Coca-Cola Company in Nigeria. It is Nigerian’s largest bottle of
non-alcoholic beverages and was incorporated in November 1951 as a bottling subsidiary of
the AG Leventis group with the sole franchise to bottle and sell Coca-cola products in
Nigeria. Production of Coca-Cola began in 1953 at a bottling facility in the basement of
mainland Hotel Oyigbo that same year, the first plant was commissioned at Malu road in
Apapa, Lagos.The system partners, The Coca-Cola Company owns the brands and is
responsible for consumer brand initiatives.

In 1972, the company became a public company and has its shares listed in the Nigerian
stock exchange.NBC manufactures, packages, merchandises and distributes the refreshing
Coca-Cola products to the trade partners and consumers.

The Owerri plant started its operations in 1982. Located in the capital city of Owerri in Imo
State, the Owerri plant runs Coca-Cola, Fanta, Sprite and Schweppes production lines
producing both the sugar and sugar free variant. Distribution covers all product categories.
Positioned in the heart of the eastern Nigeria, Owerri Plant affords central distribution in the
East supplying Uyo, Owerri and Aba commercial territories spread across 5 states (Abia,
Cross River, AkwaIbom, Imo and Ebonyi States) with estimated population coverage of
20.2million.

VISION STATEMENT:
To lead the Coca-Cola world by being the fastest growing business on the planet and be the
benchmark for other bottlers to emulate and learn from, and in simple terms “dazzle” the
world by what an inspired disciplined and passionate Nigerian organization can do. Also, to
be recognized externally as a leader in the community and play an important role in nation
building as a social partner of distinction.

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MISSION STATEMENT:
To be a world class selling organization and the best bottler in Africa by:

 Providing quality product through committed people delivering excellent consumer

satisfaction.
 Providing our people with a learning culture which will exploit their full potential for
growth.
 Maximizing our shareholder value while maintaining a good corporate citizen.
In achieving these, we will grow our company profitably.

COMPANY VALUES

1 W = Winning with customers

2 E = Excellence
3 C = Caring for our people
4 L = Learning
5 A = Authenticity
6 P = Performing as one

BRANCHES OF THE COMPANY

Nigerian Bottling Company (NBC) Ltd operates 8 plants in Nigeria. The bottling operations
are major purchasers of sugar, bottles, labels, marketing materials and services.

Here is a list of the 8 plants in Nigeria.

 Ikeja Plant – Lagos State (NBC Headquarters)

 Maiduguri Plant - Bornu State
 Port-Harcourt Plant - Rivers State
 Asejire Plant - Oyo State
 Abuja Plant - FCT
 Challawa Plant - Kano State
 Benin Plant - Edo State
 Owerri Plant - Imo State

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1.2.2 PLANT ORGANOGRAM

PLANT
MANAGER

PLANT PROCESS HUMAN

WAREHOUSE COMMERCIAL TRANSPORT
SAFETY IMPROVEMENT RESOURCE
MANAGER & CAPABILITY MANAGER MANAGER
MANAGER MANAGER
MANAGER

SAFETY VEHICLE
WAREHOUSE INTERNS / MAINTENANCE
MARSHALS MARKETERS CASHIER
OFFICERS NYSC OFFICER

SALES
FORKLIFT FACTORY STAFF BUS TRUCK
SECURITY REPRESENTA
DRIVERS WORKERS DRIVERS DRIVERS
TIVES

UTILITY AREA QUALITY

MAINTENANCE
PRODUCTION CONTROL
PRODUCTION
MANAGER ANALYST MANAGER
MANAGER
MANAGERS

RAW QUALITY
UTILITY SHIFT
MATERIALS CONTROL
CONTROLLER LEADERS SUPERVISOR
STORE KEEPER

QUALITY
LINE
ASSURANCE
OPERATORS
OFFICERS

POWER WATER UTILITY

GENERATION TREATMENT TECHNICI
SUPERVISOR SUPERVISOR ANS
LABORATORY INTERNS /
ATTENDANTS NYSC

GENERATOR WATER
OPERATORS TREATMENT
ANALYSTS FACTORY
WORKERS

MAINTENANCE SPAREPARTS ELECTRICAL

PLANNER STORE- ENGINEER
KEEPER

CONTRACT VOCATIONAL INTERNS /

STAFFS TECHNICIANS NYSC

AUTOMATION MAINTENANCE
ENGINEER SPECIALIST

Fig. 1: Plant Organogram

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 CHAPTER TWO

2.0 OVERVIEW OF THE COMPANY

The Nigerian Bottling Company Ltd is a member of Coca-Cola Hellenic group and the sole
franchise bottler of the Coca-Cola Company in Nigeria. The company which started in Lagos
now operates eight plants all over the country, all dedicated to bottling and selling standard
Coca-Cola products across the country and beyond. The Owerri plant situated in the capital
city of Owerri has a workforce of about 400 persons both fully and partially employed by
NBC. The plant answers to the headquarters in Lagos and is headed by a plant manager who
oversees all the activities of the plant and makes sure that all the departments are working
together to achieve maximum profit and a good customer satisfaction in line with the Coca-
Cola standards and with the mission and vision statement of the Nigerian Bottling company.

2.1 VARIOUS DEPARTMENTS IN THE ESTABLISHMENT AND THEIR

FUNCTIONS.
The departments of Nigerian bottling company Owerri plant are divided as follows with their
functions.

2.1.1 HUMAN RESOURCES (H.R.) DEPARTMENT:

This is the coordinating center of the administrative machinery of Nigerian Bottling

Company. They design and develop human skilled resources available, ensure and protect
workers welfare and are in charge of distributing workers to specific departments according
to their qualifications. They also query and discipline erring workers to ensure the smooth
operation of plant activities. The HR department is also in charge of issuing workers identity
card or recalling them if necessary. The H.R. department also has the financial department as
its sub-unit. This department is in total control of all financial transactions such as
preparation of accounting reports, payment of salaries and disbursement.

2.1.2 QUALITY CONTROL DEPARTMENT:

This department deals with quality control and analyzes lab test and results. They are in
charge of ensuring that the raw materials and finished products met with the specific Cola-

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Cola standards both qualitatively and quantitatively. The Quality Assurance department
controls a series of labs such as the sensory lab, the micro lab and the general lab which work
in synergy to ensure product standards.

The Quality Control department also has a Food safety unit that ensures that proper hygienic
rules and procedures are followed before, during and after the production of products.

2.1.2.1 FOOD SAFETY UNIT

This is a sub division of the Quality Control department that covers all the safety procedures
between the arrivals of raw material, syrup mixing to the distribution of finished goods. Food
safety requires that the Coca-Cola standards and specification of each and every of their
products must be met during and after production. They ensure that the production lines are
kept sparkling clean and fumigated from time to time and that hair nets, nose masks and lab
coats are worn by everybody before entering the production areas, labs or other sensitive
places. They also make sure that the equipment, and machines used for production are
thoroughly cleaned, sanitized and inspected every week and that storage units such as raw
materials store and warehouse for finished goods are kept orderly and clean. Food safety is
also responsible for testing/checking every raw material that comes into the plant to make
sure that they meet the required standard before acceptability.

2.1.3 PLANT SAFETY DEPARTMENT:

Safety is a state in which hazard and conditions leading to physical, psychological or material
harm are controlled in order to preserve the health and wellbeing of individuals and the
community. Safety is the state of being “safe”, the condition of being protected from harm or
other dangers.

The Nigerian Bottling Company, Owerri plant practices two types of safety procedures which
are food safety and environmental safety. Food safety is overseen by the department of
Quality Control while environmental safety is managed by the Plant Safety department and
overseen by safety marshals.

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They also mount surveillance on hazard prone areas in the plant in order to reduce fire risk. It
conducts safety seminars to staff and workers of the establishment from time to time in order
to equip them with the knowledge of how to behave in case of an emergency.

2.1.3.1 ENVIRONMENTAL SAFETY PRACTICES

This specifies how everybody should behave around the plant to avoid injury to self or others.
They include the following rules:

 Keep all work areas clean and tidy

 Clean-up spillages and wet floors immediately
 In case of fire alarm, follow the emergency exit procedure
 Unauthorized personnel are not allowed in restricted areas
 Before embarking on any job, obtain a work permit
 Use the rails when going through the stairs
 Always use the proper tools for any job
 Always wear the proper PPE for any job like; helmet, hand gloves, face mask, safety
boot, reflective/safety jacket, goggles, ear plug, face shield etc.
 Always shut down live equipment before working on them
 Ensure that chemicals are properly labeled and stored
 Stop work when there is need to address hazards
 Never embark on any work if you are not certain of the outcome
 Use designated pedestrian paths when walking around the plant
 Every reversing vehicle must have a lookout
 Always tag-out faulty or out-of-use equipment
 Before working at heights, obtain a height permit
 Put a caution sign when working with equipment or at places that might cause injury.
 Wear ear muffs or ear plugs when operating noisy machines or equipment
 Follow the standard procedure for any work, do not cut corners!
 See something, say something, do something

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Fig 2:: A model worker in NBC plant

2.1.4 SECURITY DEPARTMENT

DEPARTMENT:

This department works diligently on it

itss duties in protection of lives of staff and property
within the plant and environs. They are also in charge of induction and orientation of first
timers after which induction cards are issued to them depending
nding on their purpose of visit.
visit The
induction cards serve as a gate pass. They keep a daily log of visitors and workers that
entered the plant and their time of exit.

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They also keep off unwanted persons from the pant. Such persons may be personnel who
have committed one form of atrocity or the other in the plant like stealing of products or
unlawful use of violence and are consequently banned from entering the plant premises. They
also check plant workers when they enter the plant and when they are going home to ensure
that no one is smuggling anything into the plant or smuggling one out.

2.1.5 COMMERCIAL DEPARTMENT:

This department is in charge of all daily sales and various commercial activities of the
establishment. They control the marketers and sales representatives and also keeps track of all
the goods that left the plant and why.

2.1.6 MANUFACTURING DEPARTMENT:

Also called the production department. This department takes care of all the production
activities from the mixing of syrup to the palletizing of finished goods. The department is
perhaps the most important department in the plant because every activity revolves around
production. The manufacturing department runs four lines namely: Line 3, Line 5, Line 6 and
Line 7

2.1.6.1 LINE 3: This line produces both the big and small Eva water. It is an
automated PET Line that runs on Krones machines

2.1.6.2 LINE 5: This is a Returnable Glass Bottle (RGB) Line that operates on
Krones machines. It produces 50cl soft drinks with their variants. It is an
automated line that can produce several thousand crates a day.

2.1.6.3 LINE 6: This is another Returnable Glass Bottle (RGB) Line. It operates on
Krones machines and produces the 35cl Coca-Cola products. It is an
automated line and can produce several thousand crates a day. On 5th May
2019, Line 6 Owerri plant recorded a breathtaking production of 28,000 cases
a day and entered into the NBC hall of fame.

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2.1.6.4 LINE 7: This is a PET line that runs on Sidel machines. It is a highly
automated line that operates with the least human supervision among all the
lines. The line 7 produces 35cl and 50cl plastic bottled minerals with their
variants. On 7th December 2021, Owerri plant Line 7 recorded a breathtaking
production of 33,500 cases for a full day run and entered into the NBC
performance hall of fame.

2.1.6.5MACHINES USED BY THE MANUFACTURING DEPARTMENT

Mixers: Also called blenders. Used for blending the various constituents of the product
together

Blow mould: Used to blow the preform to what we know as plastic bottles

Conveyors: This is a series of chain belts operated by a motor which moves the products
from one section to the other during production

Fig 3: Conveyors

Labeler: For the application of customized labels around the bottle

Filler: This is a machine that fills up the drink to level

Wrapper: This is mostly used in PET lines. It is for the packaging of PET drinks

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2.1.6.6 PRODUCTS FROM THE MANUFACTURING DEPARTMENT

These are the Coca-Cola

Cola products manufactured by NBC alongside their various variants:
Coca-Cola,
Cola, Fanta, Sprite, Eva Water, Five Alive, Schweppes, Monster, Limca, Predator
Gold.

Fig. 4: Products of the Coca-Cola

Cola Company Nigeria

2.1.7 TRANSPORT DEPARTMENT

The transportation department oversees everything about the official vehicles of the plant. It
is divided into two sub-departments:
departments: The Fleet department and the Logistic department.
 The Fleet department: This department oversees fleet maintenance, fleet services
and management (including repairs).

 Logistic department: This department oversees transportation of finished goods,

supplies
upplies of raw materials and warehousing. This department acts as the middlem
middleman
between the manufacturing department and the commercial
ial department

2.1.8 MAINTENANCE DEPARTMENT:

Maintenance is a body that houses engineers that ensures that the plant is running smoothly
especially all that has to do with mechanical, electrical and electronics. The engineering team
houses engineer from different departments but mainly electrical and mechanical. Members

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of this department are headed by the maintenance manager who oversees all the actions of the
team. The major work of this department is to keep, preserve and protect
appliances/equipment and machines in the plant from being damaged.

2.1.9 UTILITY DEPARTMENT:

This department, just like the Maintenance department, maintains, repair and operate/control
the plant’s utility facilities such as water, power, cooling and air drying. They are basically in
charge and produce Compressed air, cooling and refrigeration, Steam, Carbon dioxide (CO2),
Electricity, raw water production and water treatment, Air Conditioning.

They are also in charge of the Water treatment plant (WTP) and partly in charge of the
Effluent treatment plant (ETP)

2.1.9.1 THE WATER TREATMENT PLANT

Water is the major ingredient in all soft drinks including Coca-Cola. An 85% all Coca-Cola
products consist of water. Line 3 which produce Eva water, uses almost 98.5% of water as
the major ingredient. They practically bottle the water for export purposes. Therefore, since
Coca-Cola is selling water to the world, it is very necessary that the water is of the purest
quality and meets both the Cola-cola standard, local and international standards. NBC Owerri
has a water treatment plant that oversees raw water generation and treatment before it can be
used for any production or industrial purposes

2.1.9.1.1 SOURCES OF WATER

There are two main sources of raw water: Surface water and Ground water

i. Surface water: Surface water is water that collects on the ground or in a stream,
river, lake, reservoir, or ocean. Surface water is constantly replenished through
precipitation and lost through evaporation and seepage into ground water supplies.
Surface waters have low dissolved solids, pH neutral, high suspended solids and
changes due to seasons and climates. (Howell et al 2010)
ii. Ground water: Groundwater is water located beneath the surface of the earth. The
water that your well draws from under the ground is an example of groundwater. It is
water that exists beneath the earth's surface in underground streams and aquifers.

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 Ground water has high dissolved solids, pH can be low, they have low suspended
solids and high in iron and manganese

Water used by Coca-Cola can be gotten from any of the above-mentioned sources but in
Owerri Plant, borehole is the source of water used.

2.1.9.1.2 WHY TREAT WATER?

In NBC, water is treated to achieve the following:

1. To remove impurities in water

2. To ensure consistency in water quality from plant to plant
3. To sustain the quality of Coca-Cola company’s products
4. To meet with international standards

2.1.9.1.3 WATER IMPURITIES

Impurities in water can either be:

Chemical,

Physical or

Microbiological impurities

2.1.9.1.4 STAGES OF STANDARD CHEMICAL PROCESS

i. Chlorination
ii. Alkalinity reduction
iii. Coagulation/flocculation

2.1.9.1.5 NBC WATER TREATMENT PROCESS

NBC Owerri has three deep boreholes of varying lengths that generates water from the
ground which in turn sends them to a 500m3 Tank called the raw water tank and from there
proceeds to the water treatment plant.

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In each borehole, there is a chlorine dosing point through which chlorine of concentration 1 –
3ppm is dosed automatically into the water being generated and they proceed to the Raw
water tank for storage. The chlorine serves to kill the germs and disinfect the water. The raw
water tank sends the water to the pump room which pumps the water to various parts of the
plant for purposes such as washing and cleaning. The water which is to be used for
production and industrial purposes are then pumped to the water treatment plant through a
pipe known as the infeed pipe. As the water proceeds to the first stage of treatment which is
the sand filter, various chemicals – FeCl3 and NaOH - are dosed automatically into the pipe
through an injection point along the way to coagulate the microscopic properties and to
increase the pH level of the water to near neutral respectively. The water and chemicals then
pass through the static mixer which creates turbidity to mix the water thoroughly with the
chemicals. Because of the presence of the chemicals, the microbial impurities and unsettled
floc particles in the water coagulates to form floating aggregates which then cluster together
and moves into the Sand filter for filtration.

The sand filter has a capacity of 25m3/h. It is filled with sands of varying diameters. The
bigger ones of about 4mm are at the base, followed by smaller ones of about 4 – 2mm, 2 -
1mm then 1 – 0.5mm. The infeed water goes into the sand filter tank and passes through the
sands to come out filtered and free of the microbiological properties. The water then proceeds
to the Intermediate tank for holding, and from the intermediate tank proceeds to the Carbon
purifier. Water in the intermediate tank is also used for backwashing of carbon purifier and
sand filter and the backwash effluent goes to the ETP. In the carbon purifier, the water is
stripped of any remaining chlorine content and odor. This is achieved by passing the water
under pressure through a bed of activated carbon in the carbon purifier. From the carbon
purifier, the water goes into the Water polisher. This contains paper or wound fiber cartridges
to remove any particles of carbon that may have passed through the supporting bed of the
carbon purifier. The treated water now goes to the lines for use.

- 15 -
Fig 5: Treated water filtration process

2.1.9.1.6 TEST POINTS

The intermediate tank is automatically programmed to call for water when the water level is
at 60%. With this, the whole process starts running repeatedly. At some stages before and
after the sand filter and before and after the carbon purifier, several tests are taken at every
one-hour interval to determine the quality of the water being treated. The points at which the
samples for the test are collected are called test points. The four common test points are:


 Infeed to sand filter test point: This is before the water goes into the sand filter
 Ex sand filter test point: This is immediately after the sand filter
 Infeed to carbon purifier: This is before the water enters the carbon purifier from the
intermediate tank
 Ex carbon purifier: This is immediately after the polisher

The following parameters are usually looked out for during the test: Turbidity, appearance,
Chlorine level, odor, Iron content, pH, Alkalinity (ppm), colour, hardness

After the polisher, the water is now treated water. The sample collected at this test point is
expected to reach the Coca-Cola standard or goes through a bypass and be retreated.

- 16 -
Fig 6: Intermediate tank

Fig 7: Raw water tank

- 17 -
2.1.9.1.7 STANDARD RESULT OF NBC TREATED WATER

The followed test result is to be achieved for the water to be considered standard water for
production:

 Appearance: Clear
 Odor: odorless
 Taste: Tasteless
 M-Alkalinity (ppm): < 85
 pH: 6.5 – 8.0
 TDS (Mg/t): < 500
 Chlorine (ppm): 0.0
 Hardness (mg/t): < 100
 Turbidity: < 0.3

2.1.9.2 THE EFFLUENT TREATMENT PLANT (ETP)

The utility department is also partly in charge of the Effluent treatment plant. In NBC Owerri,
every wastewater goes through the ETP.

Effluent is sewage that has been treated in a septic tank or sewage treatment plant. It is also
referred to as “trade effluent” or “wastewater.” It is also defined as waste other than waste
from kitchens or toilets, surface water or domestic sewage. It can be produced and discharged
by any industrial or commercial premises. (Dick, 2012)

The Effluent Treatment Plant (ETP) is a process design for treating the industrial wastewater
for its reuse or safe disposal to the environment. It is a method which is particularly designed
to purify industrial waste water for its reuse and its aim is to release safe water to
environment from the harmful effect caused by the effluent. (Johnson, 2008)

NBC treats effluent for the following reasons:

i. To reduce the usage of fresh water

ii. To preserve natural environment against pollution

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 iii. To meet the standards for emission of pollutants set by the Government & avoid
heavy penalty.

2.1.9.2.1 TYPES OF DRAINAGES

In NBC Owerri, wastewater leaves the plant through two special types of drainages:

 Storm water drain

 Process water drain
i. Storm water drain: These drainages are only found in open places in the plant. They
are usually open or partially closed. They are used for channeling rainwater outside
the plant to avoid flooding. The water in this drain does not undergo any type of
treatment.
ii. Process water drain: These types of drain are used only for the passage of industrial
wastewater to the ETP. They are usually well covered and are found in the production
lines, water treatment plant, boiler rooms and any other part of the plant where
effluent can be produced.

2.1.9.2.2 NBC EFFLUENT TREATMENT PROCESS

The effluent to be treated is gotten from product spillages and wastages in the production
lines, blow-down water from the boiler rooms, backwashed effluent from the Water treatment
plant, and water from the RGB washers. The RGB washers’ uses caustic soda (NaOH) to
wash the bottles and therefore making the wastewater in the Process water drain to be very
high on alkalinity levels. These waters flow through the process water drain to converge at
the pump station from where the wastewater is pumped to the ETP. At the ETP the effluent
goes through the following processes.

A. Preliminary Treatment: Its objective is physical separation of large sized contaminants.

For example, bottles, paper, plastics, wood logs etc. This level/process include:
i. Screening: This is the first unit operation that occurs in wastewater treatment
plants. A screen is a device with uniform openings and its purpose is to
remove large floating solids.

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 ii. Sedimentation: It is a physical water treatment process using gravity to
remove suspended solids from water.
iii. Grit Chamber: The wastewater that moves into the grit chamber removes the
dense inorganic solids such as gravel, metal fragments and sand which have
made their way into the sewers. Removal of grit can prevent damaging of
pumps & operational difficulties.
iv. Pre sedimentation tank: These are tanks built with mechanical means for
continuous removal of solids being deposited by sedimentation before
biological treatment.

B. Primary Treatment: Its aim is the removal of floating and settle-able materials such as
suspended solids and organic matter. In this treatment both physical and chemical
methods are used. It includes:
i. Flocculation: Flocculation is a physical process and does not involve the
neutralization of charge. It involves the addition of destabilized particles
together into large aggregates so that they can be easily separated from the
water.
ii. Coagulation: is a process in which coagulants are added for the purpose of
rapid settlement of minute solid particles in a liquid into larger mass. It
permits particle removal by sedimentation and for filtration. Aluminum
Sulphate or ferric chloride is the coagulant normally used here
iii. Neutralization: The main purpose of this process helps in maintaining the pH
range of 6-9 to meet the requirements of different processing units in ETP
system. The RGB washers’ uses caustic soda (NaOH) to wash the bottles
therefore making the wastewater in the Process water drain to be very high on
alkalinity levels. In the Equalization tank, the process engineers will do a pH
adjustment to correct the alkalinity level of the wastewater and neutralize it.
Hydrochloric acid (HCl) is used here because of the high alkalinity level of the
wastewater.
iv. Primary Clarifiers: These are used to slow the velocity of the water to a
point where organic solids will settle to the bottom of the tank and it contain
an equipment that is used to remove floating solids and greases from the
surface.

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C. Secondary or Biological Treatment: The objective of this treatment is the further
treatment of the effluent from primary treatment to remove the suspended solids and
residual organics. In this step biological and chemical processes are involved.
i. Activated Sludge Process: This is used for treating industrial waste water
using air and a biological floc composed of bacteria.
ii. Aerated Lagoons: Is a treatment pond provided with artificial aeration to
promote the biological oxidation of waste water. In NBC Owerri, two blowers
(blower 1 and blower 2) are used the aerate the Equalization tank
iii. Trickling Filters: Trickling filters, also known as sprinkling filters, are
commonly used for the biological treatment of domestic sewage and industrial
waste water. They contain microbes that destabilize the organic nature of the
wastewater. NBC Owerri has two trickling filters
iv. Rotating Biological Contactor: It involves allowing the wastewater to come
in contact with a biological medium in order to remove pollutants in the
wastewater before discharge of the treated wastewater to the environment.

D. Tertiary/advanced/disinfection treatment: The purpose of tertiary treatment is to

provide a final treatment stage to raise the effluent quality to the desired level before it is
reused, recycled or discharged to the environment.
i. Chemical Coagulation and sedimentation: It is used to increase the removal
of solids from effluent after primary and secondary treatment.
ii. Filtration: The clarified wastewater is first passed through the adjacent
filtration plant which contains large filter blocks to ensure high quality water.
iii. Reverse Osmosis: In this process, pressure is used to force effluent through a
membrane that retains contaminants on one side and allows the clean water to
pass to the other side.
iv. UV Disinfection: It is considered as an ideal disinfectant for industrial waste
water. It leaves no residual disinfectant in the water by ensuring the water
quality. It does not produce any disinfection by-products.

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 INFLUENT STATIC OIL LIFT SELF
POINT SCREEN SEPERATOR PUMPING CLEANING
STATION DEVICE

EQUALIZATION
PUMP DRY TANK AND pH
STATION COMPOST ADJUSTMENT
TRANSPORTING

SLUDGE BEDPRESSING CONSTANT

THICKNER MACHINE FLOW PIT

SCUM PRE-
PIT SEDIMENT
SLUDGE ATION
THICKNER SLUDGE TANK
PIT

BIOLOGICAL
TANK 1

SLUDGE
TANK
BIO TOWER 1
(TRICKLING
FILTERS)

SCUM
PIT
SEDIMENTA
TION
SLUDGE TANK
PIT

DISCHARGE BIOLOGICAL
TO SCUM SLUDGE TANK 2
RIVER PIT PIT

DISCHARGE FLOW CLARIFIC DEGASS- BIO TOWER 2

PUMPING MESURE ATION ING PIT (TRICKLING
STATION MENT TANK FILTERS)

Fig. 8: Block diagram of the Effluent Treatment Plant, NBC Owerri.

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2.9.1.3 INDUSTRIAL REFRIGERATION

The utility department is also in charge of industrial refrigeration in NBC Owerri.

NBC is classified as a Food and Beverage Industry. It makes use of cooling in a very large
extent. The cooling system available, which is the glycol chiller system, runs 24/7 as long as
production processes are taking place. This prevalent system is highly automated and as such
contributes much for a more effective output for the overall production process.

Refrigeration or cooling process is an essential unit operation which is the removal of

unwanted heat from a selected object, substance, or space and its transfer to another object,
substance, or space. Fundamentally it is a thermodynamic process which involves the
lowering of the temperature of fluids or substances in order to achieve a particular processing
purpose.

2.9.1.3.1 REASONS FOR INDUSTRIAL REFRIGERATION IN NBC

 For the preservation of raw materials thereby prolonging their lifespan.

 For product cooling.
 For air conditioning purposes

2.9.1.3.2 MACHINERY EQIPMENT AND SUBSTANCES INVOLVED

Chemical Substances Involved In the Process:

 The Refrigerant (Ammonia)

 The coolant (Propylene glycol)
 Water

Machines Involved In NBC Industrial Refrigeration:

 The Compressor
 The condenser
 The Expansion valve
 The evaporator
 Glycol tank
 The AHU

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Other equipment involved in the process:

 Pumps
 Valves
 Gauges

THE REFRIGERANT

A refrigerant in a refrigeration system serves as a working fluid which produces the actual
effect of cooling by undergoing a repetitive change in its physical state throughout the entire
loop of the process. The dehydrated pure Ammonia (R-717)is a liquid which is clear like
water with pungent smell. As a natural substance, Ammonia is environmentally benign.Its
heat absorption per volume is unrivalled. This alone allows its application in smaller
components- no need for huge cooling plants. Other attractive features include high critical
point, high coefficient of performance and low molecular weight. It has zero ozone depletion
and zero global warming potential. At atmospheric pressure, its boiling point is about - 33°C
(The crankshaft publisher, 2017)

Under the conditions ruling in refrigeration machines, it does not disintegrate in hydrogen
and Nitrogen. Therefore, refrigerant losses are not caused by disintegration but by leakages in
the plant.

Like other refrigerants, Ammonia has its undesirable side. For example, it has harmful effects
on the skin, eyes and throat. (Brucker et al, 2015)

THE COOLANT

The primary purpose of glycol is to help the system stay as consistently cold as possible
without freezing. When glycol is mixed with water, the freezing point of the water drops as
low as -60 degrees Fahrenheit. Propylene glycol, a food-grade antifreeze, is typically used
when consumable products are involved. Getting the ratio of water to glycol right is crucial to
maintaining your chiller at peak performance.

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THE COMPRESSOR

A compressor is basically a mechanical equipment that increases the pressure of a gas by

reducing its volume. It operates on the Boyle’s law which states that:

“The absolute pressure exerted by a given mass of an ideal gas is inversely proportional to
the volume it occupies if the temperature and amount of gas remain unchanged within a
closed system” (AC and heating connect, 2013)

The compressor is the starting point of the refrigeration cycle. It initiates the flow of the
refrigerant round the system, acting as a pump. The compressor compresses the refrigerant
(gaseous Ammonia) and sends to it to the condenser under high pressure and temperature.
The process is known as compression (The crankshaft publisher, 2017)

Fig. 9: The Hansa cooling unit showing both the compressor and evaporator

THE CONDENSER

The condenser is a heat exchanger. After the compressor, the hot vapor refrigerant enters the
next stage of the cycle, condensation. During the condensation stage, the refrigerant enters a
condenser and flows through a series of S-shaped tubes. As the hot vapor flows through the
condenser, cool air is blown across the tubes by a fan and gets rid of heat from the system. In
doing so, the gas liquefies and proceeds to the expansion valve

- 25 -
Fig 10: Illustrative diagram of the condenser

EXPANSION VALVE

The expansion valve serves to remove the pressure in the system thus making the fluid boil.
In doing so, a two phase mixture of gaseous and liquid is produced and the mixture proceeds
to the evaporator. The expansion valve also controls the amount of refrigerant released into
the evaporator and is intended to regulate the super heat of the refrigerant that flows out of
the evaporator to a steady value.

EVAPORATOR

The evaporator is located just after the expansion valve and just before the suction line which
goes into the compressor. The evaporator is the cold side of the system. The cold low-
pressure mixture of liquid and vapor travels through the evaporator where it vaporizes
completely as it accepts heat from the surroundings before returning to the compressor as a
low-pressure low temperature gas to start the cycle again. A fan forces air across the

- 26 -
evaporator’s fins, cooling the air by absorbing the heat from the space in question to the
refrigerant. The process is known as evaporation (Johnson, 2008)

Fig 11: diagram of the evaporator

2.9.1.3.3 WORKING PRINCIPLE - THE REFRIGERATION CYCLE

This is a thermodynamic cycle which greatly abides by the indispensable principles and
concepts
pts found in thermodynamics. According to the second law of thermodynamics heat
cannot spontaneously flow from a colder location to a hotter area; work is required to achieve
this. A cycle involving the compression, condensation, expansion valve and evaporation is
known
own as the refrigeration cycle. (Alt house, 2004)

Fig. 12: The Refrigeration cycle Fig. 13: T- S Diagram

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GLYCOL STORAGE TANKS

These are used to store the mixture of glycol and water. Getting the glycol concentration ratio
correct ensures that the freezing point is lowered enough and works smoothly in your system.
It is recommended never to use less than 25% glycol. NBC Owerri uses a 60/40 ratio in terms
of glycol to water concentration. Once you have the ratio right, the machine will work
smoothly for a long time.

The glycol tank sends the mixture at normal temperature through a pump to the evaporator
where it exchanges cooling with the chilled refrigerant and returns as chilled water. The
glycol tank also sends the chilled water through another pump to the Air handling unit (AC
and heating connect, 2013)

THE AIR HANDLING UNIT (AHU)

The AHU stands for Air Handling Unit, also known as Air Handler. It is part of the Heating,
Ventilation, and Air Conditioning (HVAC) system. The chilled glycol mixture from the
glycol tank enters into the AHU through the cooling coils. The Air handlers connect to
a ductwork ventilation system that distributes the conditioned air through the entire plant and
returns it to the AHU. This provides a better quality of air indoors and involves the removal
of moisture, smoke, odours, heat, dust, airborne bacteria, carbon dioxide, and other gases as
well as temperature control and oxygen replenishment.

Fig 14: picture of the AHU

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HOW DOES THE AHU SYSTEM WORK?

Air Return: The air return is the part of the system that marks the starting point of the
ventilation cycle. This return sucks in air, draws it through a filter, and then passes it into the
main system. We make sure we dust the returns frequently as debris and dust can easily build
up on the filters.

Filter: The filter is the second part of the air return in which the air is drawn through. We
make sure we change the filters regularly to keep the system in tip-top
top shape.

Ducts: The ducts are the channels in which the heated or cooled air passes through. We get
the ducts cleaned every 2 to 5 years in order to keep everything in working condition.

Electrical Elements: This part of the system can be a bit trickier, but often problems
originate here first. If something isn’t working right, we check for a tripped breaker or dead
batteries in the thermostat.

Coils: Usually, another part of the outdoor unit coils cool the air as it passes through with a
little help from the refrigerant. We check the coils annually. If they freeze up, we check the
filter and/or refrigerant levels.

Blower/fan: The blower draws in the air through the main section of the unit and then push
this out into the ductwork around the buil
building. The more efficiently this air moves through,
the more durable the system will be. Across the fan we’ll also have a pressure sensor, this
will sense if the fan is running.

Fig 15:: internal picture of the AHU

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GUAGES

Differential Pressure Gauges are used in the chiller system to measure the prevailing
pressures of the operating fluid at the different stages and time.

These gauges can vary in type depending on the maximum or allowable pressure that can be
attained or considered standard and within range (for a safe condition to be thought of during
the running period of the system).

The preferred gauges in the plant are basically liquid filled, long-term stable, and vibration
protected.

As indispensable, every chiller unit in the plant has three gauges mounted on the panel: -

a. Suction Pressure Gauge – this measures the pressure at which the cold refrigerant
vapor enters the compressor to get compressed by the cylinders. It is the input
pressure into the compressor.
Range = 2 – 3 bars
b. Discharge Pressure Gauge – this measures the discharge pressure of the compressed
vapor. It is the output pressure of the vapor from the compressor which further enters
the condenser (this is also the input pressure into the condenser).
Range = 5 – 7 bars
c. Oil Pressure Gauge – This measures the pressure of the lubricating oil in the internal
moving parts of the compressor – the crankcase.
Range = 10 – 15 bars

On the point of the compressor considered to be running safe and normal, the suction
pressure at the point of start-up of the system, has to be 2 to 3 bars less than the oil pressure.
This is to enable for the positive displacement functionality of the oil pump to help lubricate
the internal compressor parts.

Also, the discharge pressure has to be appreciably greater than the oil pressure. It is the high
discharge pressure which enables the compressed vapor to flow on itself through the piping
even against gravity through the system.

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Fig. 16: Suction pressure gauge Fig. 17: Discharge pressure gauge

PUMPS AND MOTOR

The standard practice is to use one pump per vessel that you wish to cool. In this setup each
pump is plugged into its own glycol pump controller. Each controller independently monitors
each vessels temperature and turns the pump on/off accordingly to regulate the temperature.
The controller on the glycol chilling unit itself will regulate the temperature in the glycol
reservoir ensuring that there is always cold glycol on hand to be sent out as needed in order to
cool the vessels. (The crankshaft publisher, 2017)

Fig 18: centrifugal Pump Fig19 : Electrical motor

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2.9.1.4 INDUSTRIAL STEAM GENERATION

The utility department is also responsible for the production of steam. In NBC, industrial
steam generation is one of the major processes with quite an appreciable application in
different processing or production areas. NBC Owerri uses a steam boiler called the waste
heat boiler.

2.9.1.4.1 WASTE HEAT RECOVERY SYSTEM – WHRS

Industrial waste heat is, by definition, the energy produced during industrial waste heat
processes and that is not used in the process (wasted energy or released into the
environment). Residual heat sources mainly consist of heat losses transferred by conduction,
convection and radiation from the products, industrial process equipment and the heat
released by combustion gases .

Heat losses can be classified into three categories:

1. Losses at high temperature: for all losses at temperatures above 400°C;

2. Losses at medium temperature: this category includes all losses between 100 and
400°C;

3. Low temperature losses: for all losses at temperatures below 100°C.

Usually, most of the lost heat in the high temperature range comes from the direct
combustion processes. Lost heat in the medium temperature range comes from the exhaust
gases from the combustion units and the one in low temperature range comes from parts,
products and equipment of the treatment units ( Bruckner et al, 2015).

Waste heat recovery systems (WHRS) are put in each category of loss in order to obtain
optimal recovery efficiency.

Waste heat can be rejected at any temperature; conventionally, the higher the temperature, the
higher the quality of the waste heat and the easier optimization of the waste heat recovery
process. It is therefore important to discover the maximum amount of recoverable heat of the
highest potential from a process and to ensure the achievement of the maximum efficiency
from a waste heat recovery system (The crankshaft publisher, 2017)

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2.1.9.4.2 WASTE HEAT CALCULATION FORMULA

The quantity or the amount of available waste heat can be calculated using the equation
shown below.

Q=VρCpΔT (1)

Where;

Q (J) is the heat content,

V is the flow rate of the substance (m3/ s),

ρ is density of the flue gas (kg/m3),

Cp is the specific heat of the substance (J/kgK) and

ΔT is the difference in substance temperature (K) between the final highest temperature in
the outlet (Tout) and the initial temperature in the inlet (Tin) of system.

2.1.9.4.3 WASTE HEAT BOILER

This is a heat-retrieval unit using hot by-product gas or oil from chemical processes; used to
produce steam in a boiler-type system. Also known as gas-tube boiler.

It is a boiler without its own firebox, which uses the heat of waste gases from industrial or
power equipment. The temperature of gases entering a waste-heat boiler is around350°−400°.
The gases come from the exhaust pipes of the Cummins generator powered by Compressed
Natural Gas (CNG). The waste-heat boilers is equipped with all components of a boiler unit,
with the exception of the firebox and other equipment associated with fuel combustion. The
waste-heat boilers for heating water is also called utilization economizers or pre-heaters.

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Fig. 20: Cochran WHR Boiler

2.1.9.4.4 APPLICATIONS OF STEAM IN NBC

On a general scope, generated steam in NBC can be used in any of the following process or
operation.

i. Syrup mixing: Steam is used for mixing the syrup before the addition of sugar. It
helps the concentrate to blend
ii. Bottle washing: Steam is supplied to the washers and with the help of caustic sodas,
they help in the washing of the bottles before being sent to the production lines
iii. Humidification: steam is also used for heating up the plant when needed through the
use of the AHU.
iv. Cleaning: For Cleaning, steam is used for environmental sanitation of the production
areas in order to scare away any form of bacteria or dirt that has the potential of
contaminating the products.

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 CHAPTER THREE

3.0 SUMMARY OF MY DAILY ACTIVITIES IN THE COMPANY

The Nigerian Bottling company notified me to commerce my internship on Tuesday, the

17thof August, 2021. The first day I reported to work, I was inducted at the security post after
which I was issued the food and safety induction card which would serve as my gate-pass
from henceforth. I was taken to the Human Relations department where the manager
welcomed me and I was assigned to the secretary who drilled me on the do’s and don’ts of
the plant especially in regards to safety. After which I was allowed to go home and prepare
for work the following day.

The next day, I was taken to the utility department and introduced to the head of department
who welcomed me and handed me over to the utility controller who became my industry
based supervisor. During the rest of the week, I was shown round the plant and oriented on
the need of the utility department in the plant. From there, I learnt that the utility department
is an engineering oriented part of the plant which deals with power generation, air
compressing and drying, steam generation, cooling, raw water generation and CO2. It is
called the heart of the plant. The department also controls, operates and maintains all the
machineries associated with the above mentioned processes and ensure that they are running
effectively to aid production.

The next week, I began observing some of the things that the utility technicians do and asking
relevant questions. I also began helping them out as the work progresses by fetching tools,
spare parts or equipment from any part of the plant for maintenance purposes. Also, it was
this week that I fist assisted the utility technicians on the chemical treatment of the waste heat
boiler (Cochran boiler) using the chemicals BT 530: Boiler Treatment Product and 190P:
Boiler Oxygen Scavenger. Throughout the week I also assisted them in the charging of glycol
(propylene glycol) in the glycol tank, mixing the glycol with water in the ratio of 60/40 and
checking the glycol concentration using a refractometer.

The following week, I continued observing and asking questions while utility technicians
worked on the machines and processes. That week, my supervisor gave me lectures on the
steam boiler and steam generation process. I learnt the difference between the waste heat
boiler and the fire tube boiler. I was shown what a dry run sensor is and its functions.

- 35 -
On the upper week, I started being actively involved with the machine operations and
maintenance. I was taught how to operate all the utility machines which include steam
boilers, ammonia compressors, air compressors, evaporators, condensers, pumps, cooling
towers, air dryers, and take log of their run hour readings at every two hours intervals.

Also, I learnt the steps for Ammonia leakage detection and procedures for boiler blowdown
as well as the steps taken to service an Air Conditioner.

On the fifth week of my stay in the plant, I was shown how to tube a boiler and I spent a good
part of the day cleaning the tubes of the 2930kg/hr boiler. Also I test ran it afterwards for
about four hours to make sure it was fit for normal usage.

This stream of daily activities continued and over the course of 23 weeks, I was able to learn
so many processes such as the Refrigeration cycle, water treatment processes, wastewater
treatment processes, steam generation processes, air compression and air drying processes.
Also, I became efficient in the operation of the various utility machines and equipment such
as compressors, heat exchangers, HVAC systems, boilers, cooling towers, pumps and valves
etc.

3.1 Test For Glycol Concentration Using A Refractometer

Equipment: Glycol tank

Materials: Refractometer, syringe, cotton wool

Procedures:

1. Collect a little amount of distilled water with syringe and drop on the refractometer
lens.
2. Clean the lens properly with cotton wool
3. Using string, collect a small amount of the sample (glycol). Drop two or three drops
on the lens of the refractometer.
4. Close the lid
5. Take a natural source of light and view through the eye piece
6. Take the reading at the point there is a demarcation in the blue and white colour

Result = 60.00

Conclusion: The percentage of glycol to water in the tank is alright.

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3.2 Test for Ammonia leakage detection

Equipment: Cooling compressor

Materials: Cotton wool/filter paper, P – indicator.

Procedure description:

1. Soak the cotton wool or filter paper with the P-indicator solution
2. Place the soaked cotton wool or filter paper to the suspected area of leakage
3. Observe colour change
4. Colour change to pink from colourless indicates Ammonia leakage
5. Stop leakage according to procedure on maintenance programme.

Result = Colour change from colourless to pink.

Conclusion: Ammonia leakage present

3.3 Boiler Blow-down procedures

1. Close water cock

2. Open drain and allow to blow out for a few seconds
3. Open water cock. The water should return to its correct level. If it moves slowly,
clean water cock orifice at the first opportunity
4. Close steam cock
5. Open drain cock and allow to blow for a few seconds.
6. Close drain cock
7. Open steam cock. The wastewater should return rapidly to its correct level. If it
returns slowly, clean steam cock orifice at first opportunity.

3.4 Steps to service an Air Conditioning Unit (A.C)

1. Power off the unit

2. Open the unit
3. Pump down gas
4. Disconnect the pipe fitting

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5. Service the unit
6. Clean the filters
7. Wash the evaporator
8. Connect back the pipe
9. Open gas and test leakage
10. Close back the unit
11. Power on the unit
12. Test run

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 CHAPTER FOUR

4.0 CONCLUSION AND RECOMMENDATONS

4.1 CONCLUSION

In a nutshell, this internship has been an excellent and rewarding experience. I have learnt a
lot from my training at The Nigerian Bottling Company Ltd, Owerri Plant. This great
opportunity has exposed me to the practical principles of various thermodynamic systems and
their operations

I was able to gain practical skills like the servicing and repairs of Air conditioners, the
operation of steam boilers, mechanical installation of centrifugal pumps, identification and
installation of different types of valves. I also learnt and properly understood the principle of
compressors, evaporators, cooling towers, the refrigeration cycle, air compression and drying,
steam generation, power generation, water treatment and the effluent treatment of
wastewater.

Indeed, the objectives of industrial training which were listed in page 1 of this report were
actualized and I remain grateful to SIWES for this wonderful opportunity to witness firsthand
some of the things I was taught in the class as theory

4.1.1 CHALLENGES ENCOUNTERED

As ideal as the program is, it still has its flaws. Even though my industrial training with NBC
was a huge success, the following were some challenges I encountered during the duration of
my six months training:

1. Difficulty in securing I.T placement in a relevant company

2. Getting accommodation in a strange town with no relatives even as I continued
coming to work from another state
3. The company’s inability to provide the necessary PPE for all the I.T students hence
some of us resort to buying our own materials
4. The company’s inability to pay all the I.T students
5. No supervision from I.T.F or institution during the entirety of the program.

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4.2 RECOMMENDATIONS

4.2.1 On the part of the Government:

 The government should help educate the Human Resource manager of various
companies on the need to give interns some stipends to enable them source for their
basic needs and avoid being distracted in search of money for upkeep.
 I.T.F should ensure that interns are constantly supervised to know the relationship
between their courses and areas/department they are assigned to work and know the
challenges faced by these students and ways to mitigate them.

4.2.2 On the part of school management:

 The school authorities should make sure they organize seminars at least twice before
the I.T. program commences. In this program, the importance, skills, qualities and
need of the program should be emphasized. So that students will know how to go
about the program before time.
 The school/department should liaise with some well-meaning companies/institutions
and reach some agreement to be sending their students over for internship. This will
enable the students to get placement in companies relevant to their course of study.
 The school management should also endeavor to send supervisors to the various
places of attachments where their students are doing their internship to access them.

4.2.3 On the part of the students:

 Students should participate diligently in the program bearing in mind that it has a lot
of part to play in their Cumulative Grade Point and future employability.
 Students should be aware that they are to work with experienced and trained
professionals and as such should build up their courage, stamina and disciplinary
capacities. Proper obedience, punctuality, commitment and humility are added
advantage.

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 REFERENCES

Levine, Ira. N (1978). “Physical Chemistry" University of Brooklyn: McGraw-Hill”

Howell and Buckius. (2009) “Fundamentals of Engineering Thermodynamics”, McGraw-

Hill, New York.

AC & Heating Connect (2013). “Thermostatic Expansion Values: A Guide to Understanding

TXVs”.

Althouse, Andrew (2004). “Modern Refrigeration and Air Conditioning”. The Goodheart-
Wilcox Company, Inc. p. 109. ISBN 1-59070-280-8.

Dick Kentwell. (2012) “The Brewers Association's Guide to Starting Your Own Brewery”

Johnson I., W. T. Choate and A. Davidson (2008). “Waste Heat Recovery. Technology and
Opportunities in U.S. Industry” BCS, Inc., Washington, D.C.

S. Bruckner, S. Liu, M. Laia, M. Radspieler, L. F. Cabeza and L. Eberhard (2015).

“Industrial waste heat recovery technologies: An economic analysis of heat transformation
technologies” Applied Energy, vol. 151, no. 1, pp. 157-167.

The Crankshaft Publishing (2017). “Waste Heat Recovery (Energy Engineering)”, [Online].
Available: http://what-when-how.com/energy-engineering/waste-heatrecovery-energy-
engineering/.

The Coca-Cola archives (2019)

Nzame Charles (2013). “The students industrial work experience”.

https://en.wikipedia.org/wiki/Refrigerant

https://www.compressorsunlimited.com/blog/how-a-refrigeration-compressor-works

https://www.hosbv.com/product/6517/Waterchillers/Grasso-RC-NH3-Ammonia

https://brennanheating.com/how-does-hvac-system-work/

https://blog.fhyzics.net/sop/sop-manual-for-soft-drink-manufacturing

http://www.madehow.com/Volume-2/Soft-Drink.html

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