Fernando D. Siervo PDF

ON-THE-JOB TRAINING AT HIDECO SUGAR MILLING COMPANY, INC.
MONTEBELLO, KANANGA, LEYTE
___________________________________________________________
An On-the-Job Training Manuscript

Presented to the Faculty of the
DEPARTMENT OF MECHANICAL ENGINEERING
College of Engineering
Visayas State University
ViSCA, Baybay City, Leyte
___________________________________________________________
In Partial Fulfillment
Of the Requirements for the Degree of
BACHELOR OF SCIENCE IN MECHANICAL ENGINEERING
FERNANDO D. SIERVO
April 2016
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TRANSMITTAL
The undergraduate On-the-Job Training manuscript attached hereto entitled “ON-
THE-JOB TRAINING AT HIDECO SUGAR MILLING COMPANY,
MONTEBELLO, KANANGA, LEYTE prepared and submitted by FERNANDO
DUEÑAS SIERVO in partial fulfillment of the requirements for the degree of
BACHELOR OF SCIENCE IN MECHANICAL ENGINEERING is hereby accepted.
ENGR. RAMIL L. LAURON

Adviser
__________________________
Date
Accepted in partial fulfillment of the requirements for the course MEng 199 of the
degree BACHELOR OF SCIENCE IN MECHANICAL ENGINEERING.
ENGR. RAMIL L. LAURON

Head, Department of Mechanical Engineering
__________________________
Date
\
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ACKNOWLEDGEMENT
With deepest gratitude and appreciation, I humbly give thanks to the people who,
with all that they can, helped me in making my On-the-Job Training a possible one.
To my mother, Amelia D. Siervo, for her unending love and support, for providing
all my needs financially and morally, for her patience and understanding during my tiring
days that I can’t help her in the chores, for her never fading advices and for being there for
me no matter what.
To my brothers: Jeffrey and Jomar, to my sisters: Adelina and Jullie Ann, to my
future wife, Catherine Acompañado and to my son, Prince Nathan who served as an
inspiration to me, who keep on encouraging me to always make the best out of everything
and for their being proud and ever supporting siblings to me.
To the university where I am studying, Visayas State University, where I am
continuously growing as a Bachelor of Science in Mechanical Engineering student.
To all my instructors who shared and continuously sharing their knowledge with
students like me and keep on molding me into a better person. I am extending my warmest
thanks especially to Engr. Ramil L. Lauron who, with all that he can, share with us
everything that he knows and keep on inspiring me to pursue my goals in life, most of all,
my goal to be a Registered Mechanical Engineering someday. I thank him for his patience
during the times that we commit failures and a big thanks for touching my life and
motivating me to study harder for me to have a better future.
To the Hideco Sugar Milling Company employees, for their warm welcome
to me. I am very grateful for having them as part of my On-the-Job Training. For all their
advices and for everything that they taught me during my stay with them and most of all,
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for the memories we’ve shared – the happy moments, the sorrowful ones, the rush hours,
the brainstorming and nerve-wracking days and for everything that they did that
contributed to my growth as a human being. I thank them so much.
To my friends and co-trainees, for the happiness and for being there to support me
and to comfort me whenever I have difficulties during my training. I thank them for the
friendship and teamwork and for being my companions whom I can share my laughter and
sorrows with.
Above all, to our Almighty God, for His unconditional love and for all the blessing
He is showering upon me each day of my life. With love and gratitude, I thank Him for
guiding me during my training and for making this On-the-Job Training a possible one.
For the provision and wisdom He has bestowed upon me, for keeping me and my love ones
always safe, for giving me enough knowledge and ability to perform each task that was
assigned to me and for the challenges He has given me that made me stronger than ever. I
thank Him for His comfort during the times that I am about to give up. By His grace, I was
able to finish this training without any conflict.
Thank You Very much!!!..
Fernando D. Siervo
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DEDICATION
I wholeheartedly dedicate this
On-the-Job Training manuscript to my mother Amelia, my brothers Jomar and Jeffrey,
my sisters Julie Ann and Adelina, my future wife Catherine and
my baby Prince Nathan,
to all my instructors especially to Engr. Ramil L. Lauron,
to the Hideco Sugar Milling Company officials,
to my friends and co-trainees and above all,
to our Almighty God.
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TABLE OF CONTENTS
CONTENT PAGE
TRANSMITTAL ……………………………………………………………. ii
ACKNOWLEDGEMENT ………………………………………………….. iii
DEDICATION ……………………………………………………………… v
TABLE OF CONTENTS …………………………………………………. vi
LIST OF FIGURES ………………………………………………………… viii
APPENDICES ……………………………………………………………… x
CHAPTER 1. INTRODUCTION
1.1 Importance of On-the-Job Training ………………………… 1
1.1 Objective of On-the-Job Training ………………………….. 3
1.2 Time and Place of On-the-Job Training ……………………. 3
1.3 Scope and Limitations of the On-the-Job Training ………… 3
CHAPTER 2. WORK ACTIVITIES
2.1 Application Process ………………………………………… 4
2.2 Schedule of Activities ……………………………………… 5
CHAPTER 3. DISCUSSION
3.1 THE HEDICO SUGAR MILLING COMPANY, INC
3.1.1 Company Background …………………………….. 7
3.1.2 Company Mission and Vision …………………….. 8
3.1.3 Company Policies …………………………………. 8
3.1.4 Company’s Location Map ………………………… 9
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3.1.5 Company Organizational Structure ……………….. 10
3.2 Practical Experiences
3.2.1 Boiler Department ………………………………… 12
3.2.2 Bioler Working Principle …………………………. 13
3.2.3 Steam Distribution ………………………………… 15
3.2.4 HISUMCO’s Boiler Operation …………………… 15
3.2.4.1 Starting up the Boiler …………………….. 17
3.2.4.2 HISUMCO’S Boiler Shut Down ………… 22
3.2.5 Key Components and Parts of Boilers …….. 24
3.3 HISUMCO’S REPAIR SEASON
3.3.1 Boiler Section ……………………………………… 31
3.3.2 Mill Section ……………………………………….. 33
3.3.3 Maintenance Section ………………………………. 35
3.4 Learnings of the Student Trainee …………………………… 38
3.5 Problems Encountered ……………………………………… 40
CHAPTER 4. SUMMARY and RECOMMENDATION
4.1 Summary ……………………………………………………. 41
4.2 Recommendation …….………….. ………………………… 42
4.2.1 For the Company ………………………………… 42
4.2.2 For the Future Trainees ………………………….. 43
CHAPTER 5. LITERATURE CITED 44
APPENDICES 45
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LIST OF FIGURES
FIGURE FIGURE TITLE PAGE

NO.
1 Location map of Kananga Leyte ………………………………. 9
2 Location map of Hedico Sugar Milling Company, Inc. Montebello,
Kananga Leyte …………………………………… 10
3 Hideco Sugar Milling Company, Inc. Organizational Structure.. 11
4 Front View of the Department of Boiler ………………………. 12
5 Bioler Set-up and Flow Diagram ……………………………… 13
6 Boiler Main Steam Lines …………………………………….... 16
7 Boiler Steam Generated Distribution …………………………. 16
3.1 Air Vent ……………………………………………………….. 24
3.2 Downcomer and Riser Tubes …………………………………. 24
3.3 Economizer …………………………………………………… 25
3.4 Safety Valve ………………………………………………….. 25
3.5 Desuperheater ………………………………………………… 25
3.6 Main Steam Stop Valve ……………………………………… 26
3.7 Try Cock …………………………………………………….. 26
3.8 Water Walls ……………….………………………………… 26
3.9 Gauge Glass Water Columns …………….…………………... 27
3.10 Pressure Gauge ……….. ……………………………………. 27
3.11a Force Draft Fans ……………………………………………... 27
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3.11b Turbulence Draft Fans ………………………………………... 27
3.12 Boiler Furnace …..……………………………………………. 28
3.13 Dearator …………….………………………………………… 28
3.14 Chimney ……………………………………………………… 28
3.15 Steam Traps …………………………………………………... 29
3.16 Feed Water Pumps ……………………………………………. 29
3.17 Steam Drum ………………………………………………….. 29
3.18 Soot Blower ………………………………………………….. 30
3.19 Blow Down Valve …………………………………………… 30
3.20 Main Feedwater Pump ………………………………………. 30
3.3.1a Dearator Water Inlet …………………………………………. 31
3.3.1b Boiler Furnace ……………………………………………….. 32
3.3.2a Dismantling Turbine who Drive the 2nd Set Cane Crusher …. 33
3.3.2b Assembling Turbine who Drive the 2nd Set Cane Crusher ….. 34
3.3.2c Clearing the Par Valve ……………………………………….. 35
3.3.3a Dismantling the Turbine ……………………………………… 36
3.3.3b Measuring the Clearance ……………………………………... 36
3.3.3c Bearing Housing ……………………………………………... 37
3.3.3d Cane Crush Roller ……………………………………………. 37
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LIST OF APPENDICES
APPENDIX Page PAGE
A Recommendation Letter 46 46
B Application Letter 47 47
C Resume 48 48
D Confirmation Letter 49 49
E Daily Accomplishment Report 50 50
F Company`s Daily Time Record Sheet 57 57
G Weekly Activity Report 59 59
H Certificate of Completion 60 60
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CHAPTER I
INTRODUCTION
1.1 Importance of On-the-Job Training
On-the-job training (OJT) is a form of training taking place in a normal working
situation. It is a one-on-one training located at the job site, where someone who knows
how to do a task shows another how to perform it. In antiquity, the work performed by
most people did not rely on abstract thinking or academic education. (Wikipedia, the free
encyclopedia)
The best way to learn a particular work is to do it. Even parents or community
members, who knew the skills necessary for survival, passed their knowledge on to the
children through direct instruction. (Wikipedia, the free encyclopedia) In the same reason,
most college courses requires a student to have his on-the-job training before he finishes
his degree. This course aims to train and orient students about the degree that they are
taking, as well as to give an overview of their future career. Thus at the end of the training,
students are expected to be more confident and knowledgeable in their profession.
OJT is very important to students especially to those who have no experience and
has just a little idea on how to do the job properly. Because unlike going to school to learn
things through writing, solving or reading, OJT will teach and show students the reality of
how to do and handle task or work – the reality of life. During this period of time, the
students will be exposed to the actual work which is, of course, related to the course that
they are taking. Thus, giving them the opportunity to apply and understand more the
theories and computations that they have learned in school. In addition, students will
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acquire relevant knowledge and develop skills necessary for the job as well as techniques
on how to do it through the help of the experts around them. Also, OJT will enhance the
critical thinking abilities and discipline of a student who is conducting his training in a
company. At the same time, his ability to make sound decisions and evaluate pertinent
factors will be improved. Not only that, OJT will give the trainee the chance to immerse
himself in his chosen field thus would build up his competence because it can develop
professionalism in dealing his job and the people around him. The trainee will be able to
know how to adjust with other people’s personalities and attitudes, too. This is because
while working, trainees will meet and get acquainted with the real professionals and people
having different positions in the company, either high or low. In the long run, students will
be molded to the best that they can be.
On-the-Job Training requires effort and seriousness. Every little thing that a student
learned in the training can be applied when they will have their job in the future. Therefore
a trainee should take the OJT seriously as it can be a powerful tool for a person in preparing
his next chapter in life as a professional. It can possibly be a source of recommendation
when they take that big lift from being students to career professionals someday. On the
other hand, they will also be prepared to take the battle in the competitive world because
they already have the experience to do and handle the job in line with their profession.
As what we can see, most fresh graduate who have experienced the best on-the-Job
Training while he is still a student will be confident to apply a job related to his profession
because they know that they are equipped with skills needed for that job. Thus young once
who will become the future professionals should have a proper and the best On-the-Job
Training.
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1.2 Objectives of the On-the-Job Training
This On-the-Job Training generally aims to experience the actual application of
Mechanical Engineering in the field of practice.
Specifically this On-the-Job Training aimed to:
1. Apply the theories and computation learned from school;
2. Familiarize the types of equipment in the field of study;
3. Familiarize the parts and the operation of the boiler;
4. Socialize and interact with the real professionals and people having
different positions in the company;
5. Gain practical knowledge and develop skills, work ethics, and
professionalism
1.3 Time and Place of On-the-Job Training
The On-the-Job Training was conducted at Hideco Sugar Milling Company, Inc.
located at Brgy. Montebello, Kananga, Leyte. The training started on April 20, 2015 and
ended on June 03, 2015 with an equivalent of approximately 240 working hours.
1.4 Scope and Limitations of the On-the-Job Training
This On-the-Job Training is limited only on the observation and hands-on experiences
for 44 days excluding the financial and personnel management of Hideco Sugar Milling
Company, Inc. and their other businesses.
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CHAPTER II
WORK ACTIVITIES
2.1 Application Process
First, the head of Department of Mechanical Engineering contacted the company’s
human resource officer through sending a letter, asking if they are accepting mechanical
engineering student practitioner. After knowing that the company accepts mechanical
engineering student for an on-the-job training, some important information such as
company’s address and the name of the person to whom the application letter will be sent
were gathered.
After that, a Personal Vitae and an application letter addressed to Mrs. Evelyn D.
Borela, the Human Resource Superintendent of the Hideco Sugar Milling Company, Inc.,
were submitted personally by the trainee to the company located at Brgy. Montebello,
Kananga, Leyte.
Before the field practice started, other pertinent documents were also such as,
notarized parental consent, acknowledgement and letter of recommendation from Engr.
Ramil L. Lauron, Head of the Department of Mechanical Engineering at Visayas State
University, Baybay City, Leyte.
As a proof of acceptance, a job description was then given to the student trainee
instead of Letter of Acceptance from the Human Resource officer of Hideco Sugar Milling
Company, Inc.
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2.2 Schedule of Activities
The first day of the training includes the orientation, introduction and assignments
of the trainees.
An orientation about the company, safety guidelines, rules and regulations, was
given by Engr. Fortunato C. Galos, the Operation Manager. After the orientation, the
student trainee went to the factory together with Cadet Engr. Ritche who introduced them
to PME Lino de los Santos, the Department of Boiler Superintendent, Engr. Edmund
Villasan, the Department of Mill Superintendent, Engr. Alan Niez the Department of
Maintenance Superintendent, and the other company’s personnel.
The training officially started on the first day afternoon, April 20, 2015. Student
trainees were assigned in the field works of the three different departments; Department of
Boiler, Department of Mill and Department of Maintenance in order to gain more
knowledge through hands-on and actual observation.
In the Department of Boiler, the training is focused on familiarizing the parts and
the auxiliaries of the boiler, knowing the distribution of the steam generated to the factory
and knowing the operation of the boiler.
In the Department of Mill, the training is focused on familiarizing the equipment of
the factory, familiarizing the parts, functions and the operation of the steam turbine and
assisting the mechanic by dismantling the steam turbine.
In the Department of Maintenance, the training is focused on familiarizing the types
of tools, bolts and nuts, assisting the mechanic in dismantling the steam turbine, measuring
the clearance between the babbit bearing and the shaft using the “plastigage”.
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A graded evaluation report of the trainees was done weekly by the trainee’s
Supervising Engineers, Engr. Ryan Cabelin, Engr. Joryll de Dios and Engr. Dennis Ferales.
After the whole training period, the evaluation report was forwarded for approval to the
Operation Manager, Engr. Fortunato C. Galos. After completing the field practice,
Certificate of Completion was given to the trainee by the Operation Manager Engr.
Fortunato C. Galos and undersigned by the Human Resource Superintendent Engr. Evelyn
D. Borela.
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CHAPTER III
DISCUSSION
3.1 HEDICO SUGAR MILLING COMPANY, INC.
3.1.1 Company Background
Hedico Development Corporation (HEDICO) is owned by the Cojuanco’s.
Initially, it was planned to be constructed in Hilongos, Leyte but the community rejected
the technology since the agricultural land areas were dedicated to rice farming. Later on, it
was offered and accepted in Montebello, Kananga, Leyte. The plant was constructed in
1972 with a rate capacity of 5,000 tons cane per day producing Raw sugar only. The Mills
and Power House are made in France. Its Boilers are Bobcock Made in USA while its
process Boiling House is BMA in Germany.
In February 1991, the new company, Hedico Sugar Milling Company, Inc.
(HISUMCO) took over from Hilongos Development Corporation (HIDECO). The
ownership and operation of the raw sugar mill, through a negotiated from Asset Servicing
Privatization Trust.
In 1993, HISUMCO entered into an agreement with Tate & Lyle (UK) for the
design, supply of equipment and construction of sugar refinery, adjacent to raw sugar
factory with a rated capacity of 6,000 bags refine sugar per day (300 MT/day). Its operation
was successfully commissioned on June 04, 1994.
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In 2001, a new 6 Megawatt – Turbo Generator was acquired and installed to
augment and upgraded the electricity generation capability of HISUMCO. Improvements,
modifications and additional installations were done in the past to increase productivity
and efficiency of the Plant.
3.1.2 Company Mission & Vision
Mission
HISUMCO aims to achieve and sustain a reputation for quality of raw and refine sugar in
domestic and export market while recognizing its responsibility to the natural environment.
Vision
HISUMCO visualizes that Ormoc – Kananga and its neighboring towns will become the
sugar capital of Region VIII, through converting all its barren and idle land into
Agricultural Lands for sugar cane plantations. Furthermore giving assistance for those
willing to plant sugar cane through its financial, fertilizer assistance and farm elements
usage to ensure successful cane yield.
3.1.3 Company Policies

The management implements policies so workers are well disciplined and would
know how to respect their co-workers especially the higher positioned employees. Any
violation of the rules mentioned below will lead to disciplinary action or termination of
the worker. The set rules and regulations to be followed are listed below:
1. Workers should work during the working hours.
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2. Smoking is strictly prohibited in the factory.
3. No liquor drinking during the working hours.
4. Stealing and filing of document of the company are strictly prohibited.
5. No gambling inside the factory.
3.1.4 Company’s Location Map
Figure 1. Location map of Kananga Leyte
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Figure 2. Location map of Hedico Sugar Milling Company, Inc. Montebello, Kananga Leyte
3.1.5 Company Organizational Structure
Hideco Sugar Milling Company, Inc. was formed for being trusted, responsible
with integrity and teamwork in every aspects of producing sugar in Region VIII. The
HISUMCO, Inc. was owned by Cojuanco family. This is currently headed by Mr. Julio S.
Yup and is divided into different divisions and sections as shown in Figure 3 below.
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Figure 3. Hideco Sugar Milling Company, Inc. Organizational Structure
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3.2 Practical Experiences
3.2.1Boiler Department
Exposure to the actual field of works in the field of mechanical engineering is very
important to the student trainee because it gives understanding to the real life of being a
mechanical engineer; taking obligations in a certain project and leading different people in
the field of works. On the first week, fourth week and the last week of the on-the-job
training the student trainee was assigned in the Department of Boiler (Figure 4).
Figure 4. Front View of the Department of Boiler
In a traditional context, a boiler is an enclosed container that provides heat from
combustion which is transferred into the working media (usually water) until it becomes
heated or a gas (steam). One could simply say that a boiler is a heat exchanger between fire
and water. The boiler is the part of a steam power plant process that produces the steam
and thus provides the heat. The steam or hot water under pressure can then be used for
transferring the heat to a process that consumes the heat in the steam and turns it into work.
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HISUMCO is using a water tube boiler which means that the water is inside the
tubes and combustion gases pass around the outside of the tubes. The boiler of HISUMCO
has a capacity of approximately 5000 Develop Boiler Horse Power (DBHP).
The department of boiler is headed by superintendent PME Lino de los Santos
assisted by his three supervisors, Engr. Ryan Cabelin, Engr. Rey Caro and Engr. Manatad.
During the operation they have a routine of duty to ensure and manage the operation of the
boiler. If PME Lino de los Santos is on leave, one of his supervisors will take in-charge of
his position to control and manage the flow of the boiler operation.
3.2.2 Bioler Working Principle
Figure 5. Bioler Set-up and Flow Diagram
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The boiler is consist mainly of two drums: the upper drum called “steam drum” and
the lower drum called “mud drum”. The two drums are connected with two tubes called
down-comer and riser tubes (Figure 5). Water in the lower drum and in the riser will
combust bagasse fuel which will produce heat and will then be transferred to the tubes
making the temperature raise thus resulting for the water in the upper drum to evaporate.
In the upper drum the steam is separated from water naturally and stored above the water
surface. The stored steam in the steam drum will automatically pass through the steam tube
and will then go to the super heater tubes which will leave the super heater header to the
designated area. Temporarily, the soften water in the storage tank will pump to the
deaerator with phosphate and sulfite chemicals added unto it to remove the impurities
carried by the water from the ground. Gravitationally, the water goes down to the suction
pipe of the feed water pump and leaves at the pressure enough to enter the water in the
steam drum to replace the water that has evaporated and escaped. Before the water entered
in the steam drum it was heated in the economizer (see Figure 5). When the flue gas or the
orange line hit the economizer tubes, a heat transfer will occur in the system causing the
temperature of water to rise. The water entering in the steam drum is already boiled and
carrying a vapor. The water is fed from feed water inlet at upper drum. This water is heavier
than the hotter water of lower drum. In the riser, the colder water push the hotter water
upwards. So there is one convectional flow of water in the boiler system. The superheated
steam from the boiler is used to drive the non-condensate turbines in the factory and the
exhaust gas will pass to the boiling house for cooking the mixed juice sugar. The exhaust
gas will enter to the evaporator inlet as the mixed juice sugar will pass through the fittings
inside the evaporator. Mechanically, the heat energy of the gas is enough to boil and cook
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the mixed juice sugar and thermodynamically, the gas turn into a condensate water. The
condensate water will pump into the deaerator which serve as the continuous water supply
to the boiler and the water taken from the storage tank will cut-off. Some steam taken from
the three bar lines is injected in the deaerator in order to remove the non-condensable gases
from the boiler feed water. The principal gases of concern are oxygen, carbon dioxide, and
ammonia, which are major contributors to boilers, steam turbines and condensate piping
corrosion problems.
3.2.3 Steam Distribution
The steam generated from the boiler is distributed (as shown in figure 7 below), to
the; a) boiler steam turbine with a steam flow capacity of 12-17 tons/hr which is enough to
drive the induce draft fan and the multi-stage feed water pump, b) mill section steam turbine
at second set cane knives and 5 sets of sugar mill. Each turbine can rotate around 6500
revolution per minute which is enough to drive the crushing mill and cane knives at desired
speed, c) power house steam turbine with a steam flow capacity of 38-48 tons/hr which can
drive the generator which has a capacity of 6 MW. All exhaust gas will pass to the boiling
house for cooking the raw sugar purposes.
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Figure 6. Boiler Steam Lines
Figure 7. Boiler Steam Generated Distribution
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3.2.4 HISUMCO’s Boiler Operation
3.2.4.1 Starting up the Boiler
1. Checking before lighting up
Make sure that:
 All inspection doors, explosion doors and sight glasses are closed
 All induced and forced draught fan dampers are in closed positions
 The remote controls are open properly
 All the control instruments are in working order. The control panel is switch on and
the pneumatic instrument supplied with air at the right pressure.
 All the isolating valves on the direct reading level gauges, the transmitter of the
remote reading gauge, the boiler pressure gauge, the steam flowmeter and the feed
water regulator are open.
 The blow down cocks valve are closed.
 The direct reading level gauge glasses are clean.
 All the water wall drain valves, lower drum drain valve and contentious blow down
valve are closed.
 Valve and by-pass on superheated steam outlet and manifold junction, soot blowing
steam extraction valve are closed.
When completely closed a cold shut-down, the hand wheels of the plug valves should
not be screwed down tightly to avoid expansion stresses on the steams when the operating
temperature is reached.
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 The following valves are open:
 Soot blowing piping drain
 Drum vent
 Super heater circulation and
 The safety valves
 Drain on steam header before manifold.
 A sufficient reserve water is available.
 Two feed water pumps are in working order; and
 The bagasse fuel supply is insure.
2. Filling the boiler
Lighting-up level is suited at “low level” marked on the mounting of the direct
reading water gauge. The boiler water will be conditioned to maintain the characteristics.
3. Lighting-up and pressure raising.
Lighting-up
Lighting-up may be carried out either with fuel oil when the burner installation is
fitted, or with bagasse.
When oil firing, the grate should be protected from the radiation of the flame by a
layer of ash.
When firing bagasse, reference should be made to the special instructions given by
the FAMA for operating the pneumatic spreader stoker.
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Pressure raising
 The firing should be controlled to ensure a regular and moderate increase in the
boiler water temperature, according to the gradient of not more than 45 degrees
Celsius per hour.
 Close the drum vent as soon as the pressure reaches 1.5 bars.
 Carry out extractions through to the lower drum drain valve to bring the water level
down to the medium level.
Important note: Never blow down through the water wall valves while the fire is alight in
the furnace to prevent any danger of tube failure due to a disturbance of the water feedwater
supply.
 Make sure that one feedwater pump is in operation.
 Adjust the opening of the steam flow valve according to the rise in pressure so as
to keep a flow sufficient to allow nominal design value while starting-up.
 The temperature leaves from the economizer should not be more than 150 degrees
Celsius.
 If necessary, adjust the flow of water passing through the economizer by adjusting
circulating valve.
4. While the pressure is rising make sure:
 That the pressure gauge gives connecting pipework and is not blocked up or blown
down for a ratter short time to prevent damaging the tube caused by the entry of the
steam.
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 That the pressure gauge gives accurate reading. Check the pressure with a
calibrating pressure gauge.
 That the water gauge reading is correct. Blow down the mounting at regular
intervals to warm the connection pipework. The water should go up rapidly in the
glass as soon as blowing down is finished.
 That the fire shut-down works properly when very low water level is reached.
 That the transmitter of the remote reading level indicator is in operation. Blow
down the piping before the start-up after a long shut-down and when the pressure
has reached 20 bars
 That the direct and remote indicator give the same readings.
 That the alarms for too low or too high water level operate properly and that the
levels which set them off are right. Test the operation of the alarms by changing the
gauge level deliberately.
5. Putting the steam generator on line
 When the pressure has reached 5 bars, start warming the steam piping by slightly
loosening the by-pass on the superheater outlet valves. Make sure that the drain
valve before the manifold is open and is discharged sufficiently.
 When the pressure has reached 20 bars, open the by-pass on the main stream valve
gradually until it is fully open, so as to raise the pressure slowly in the piping. When
the pressure on either size is equalized, open the main valve slowly and close the
by-pass.
 Put the steam flowmeter into operation.
 Proceed in the same way in opening the manifold steam valve.
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 Should the boiler be connected into a header into which steam is already being
discharged from other generators, the boiler should be put on line at a pressure
equal to or slightly higher than that of other units.
 When the boiler begins to deliver steam to the plant, close the circulation valve and
the steam piping drain.
 Watch the water level carefully during those operation. Close the circulation valve
on the economizer if any.
 When the steam output reaches 10 tons per hour, start the feedwater regulator, the
drought and combustion air controller and the CO2 recorder.
 Regulate the bagasse firing accordance with a FAMA directions. In an initial start-
up, or restarting after a prolonged shut-down it is preferable to restrict the steam
output during the first 24 hours to half the nominal output. This lapse of time allows
the following:
 That the various equipment is operating properly (Fans, Feeders, Pumps,
Feed Water Regulator, Sootblowers, etc.)
 That various equipment, electric switch gear in the installation working
safely. That the bagasse feed is working regularly and whether the initial
firing adjustment are correct.
 That the measuring instrument are working properly, (steam flowmeter,
temperature recorder, CO2 recorder, etc.)
 The boiler will be brought up in stage to its nominal output to test the operating
characteristics.
21
 Examine the quality of the boiler water to determine according to the results of the
analysis, the quantities of reagents to be added and the rate of the contentious blow-
down necessary to maintain the required characteristics.
 When adjustments are satisfactory, the boiler may be put into industrial operation.
6. Auxilliary Equipment
Reference should be made to the special starting-up, operating and maintenance
directions contained in instruction and it’s provided by the various supplier.
3.2.4.2 HISUMCO’S Boiler Shut Down
1. Normal shut down inspection and extended work stoppage
 Refer to FAMA instruction for the furnace shut-down.
 Check the water supply carefully during the decrease in load. Isolate the regulator
when flow is lower the 5 tons per hour and go on feeding in adjusting with of the
by-pass valve as long as the boiler is steaming.
 If the turbo alternator is shut-down use the steam pump if necessary.
 If when the boiler is not steaming any longer, close the steam pump at the manifold
and open the piping drain.
 Close the steam valve at the boiler outlet and open slightly the superheater
circulating valve.
 Shut down the induced draught fan. Keep the damper slightly open to ensure the
gas discharge.
22
 Close the contentious blow down piping.
 Supply in water up to the high level, close the by-pass and shut down the feed water
pump.
 Close the superheater circulating valve when the pressure has dropped to 5 bars.
 Let the boiler cool off slowly.
 When the pressure has dropped to 1 bar, open the drum vent valve. This is done in
order to avoid the setup of vacuum in the boiler during the cooling time which
might cause at the autoclave gaskets.
 The boiler may then be drained if necessary.
2. Temporary shut-down banking
The instruction below should be followed if shutting down lasts a few hours or a
day.
 Reduce the operating rate gradually as mentioned above.
 As soon as the steam demand is reduced to zero, shut down feeder, induced and
draught fans (primary air, turbulence, re-firing). Keep the distribution air in
operation.
 Close the steam outlet valve and open the superheater circulating valve slightly.
 Re-start up the bagasse feeder in order to cover the grate with a 30-40 cm thick fuel
bod. This fuel bod will dry and so the re-firing will be performed under the
favorable conditions.
 Shut down the distribution air fan and feeders.
 Keep the induced draught damper slightly open in order to not pressurize the
furnace.
23
 Close the superheater circulation valve when the pressure dropped to 5 bars.
 After the boiler has been shut down for one hour, the lower drum and water wall
drain valves should be opened for a short period time in order to get rid of the
possible deposits. The operation is to be renewed after four hours and before
restarting up the boiler.
 Supply the boiler in water if necessary in order to keep seeing the level in the gauge.
Note: A boiler kept under hot storage condition should imperatively remain under the care
of the operator.
3.2.5 Key Components and Parts of Boilers
Air Vent – allows air to be released from the
boiler prior to cutting in the boiler on the line
and to break the vacuum when the boiler is
being emptied.
Fig 3.1 Air Vent
Downcomer and Riser Tubes – a large tube or
pipe connecting to the water space of the
drum to the water drum.
Fig 3.2 Downcomer and Riser Tubes
24
Economizer – feed water pre-heating device which
utilizes the heat of the flue gases.
Fig 3.3 Economizer
Safety Valve – a safety device which
automatically release the steam in case of
over-pressure.
Fig 3.4 Safety Valve
Desuperheater – is a device for removing
the superheat from the steam. It is
ussually consist of coil of piping
located in the steam drum below the
normal steaming water level.
Fig 3.5 Desuperheater
25
Main Steam
Stop Valve – allows the steam to leave the
boiler pass into the auxilliary steam
line and from there, to the main
turbine.
Fig 3.6 Main Stream Stop Valve
Try Cocks – attached to the shell or to the
water column and are used to prove the
reading indicated by the gauge glass.
Fig 3.7 Try Cocks
Water Walls – water tube installed in the
furnace to protect the furnace against
high temperature and also serve an
extension of heat transfer area for the
feed water.
Fig 3.8 Water Walls
26
Gauge Glass
(Water Column) – indicate the water
level existing in the boiler.
Fig 3.9 Gauge Glass
Pressure Gauge – indicates the pressure of the
steam in the boiler.
Fig 3.10 Pressure Gauge
Draft Fans – supply air needed for the combustion and create the draft required for the
flow of gases in the boiler.
Fig 3.11a. Force Draft Fan Fig 3.11b. Turbulence Draft Fan
27
Furnace – encloses the combustion
equipment so that the heat generated
will be utilized effectively.
Fig 3.12 Boiler Furnace
Deaerator – a special case of feed water
heater that is designed to promote the
removal of non-condensable gases from
the boiler feed water.
Fig 3.13 Deaerator
Chimney – vertical vent used to transfer
exhaust products from a boiler or
furnace to the outdoors.
Fig 3.14 Chimney
28
Steam Traps –installed throughout steam
systems to remove condensate (spent
steam), air, and non-condensable gases from
the steam system.
Fig 3.15 Steam Traps
Feed Water Pumps – delivers water to
the boiler.
Fig 3.16 Feed Water Pumps
Steam Drum – a standard feature of water-
tube boiler. It is a reservoir of water/steam
at the top end of the water tubes. The drum
stores the steam generated in the water tubes
and acts as a phase-separator for the
steam/water mixture.
Fig 3.17 Steam Drum
29
Soot blower – device which uses steam or
crompressed air to remove the soot that
has accumulated in the boiler tubes and
drums.
Fig 3.18 Soot Blower
Blow Down Valve – allows sediments to be blown off
from the bottom so that the density of the water may be
measured.
Fig 3.19 Blow Down Valve
Main Feed Water Valve – permits or prevents
entrance of feed water stop valve. Located
in the auxiliary feed water line.
Fig 3.20 Main Feed Water Valve
30
3.3 HSIMCO’S REPAIR SEASON
HISUMCO, Inc. is the largest raw sugar mill in Leyte. They can produce more than
one tausand sacks of sugar per day during the crushing season. From 1990’s to 2014, the
crushing season of HISUMCO generally lasts about six months. However, beyond 2014 to
the present years the crushing season lasts only about three months. This is because of the
effect of “Yolanda” typhoon. After the crushing season, the factory will shut-down and
that’s the time that they will check and repair all the equipment in the factory.
During the repair season, the student trainee was permitted to do hands-on or actual
observations in order to know well the different equipment in the factory.
3.3.1 Boiler Section
The student trainee measured
the diameter of the water inlet inside
the deaerator to compute the correct
compression of the spring needed for
the water to enter in the deaerator at 20
psi.
Figure 3.3.1a. Deaerator Water Inlet
31
Figure 3.3.1b Boiler Furnace
The furnace is a component of the boiler that provides the heat that heats the
water of the system. HISUMCO is using bagasse as a fuel in the furnace. Due to high
temperature after the combustion process, the ash attached in the water tubes becomes
“clench” resulting to low heat transfer between the flow gas and water tubes. Every repair
season, the boiler management wants to remove the clench so that there is a great efficiency
of the boiler performance.
During the training, the student trainee was part of the activity by removing the
ash and the clench inside the furnace. This was done for almost three weeks.
32
3.3.2 Department of Mill
The department of mill is headed by Superintendent Engr. Edmund Villasan and
assisted by his three supervisors, Engr. Jovani, Engr. Joryll de Dios and Engr. Alex. During
the milling season they are the in-charge to control all equipment using in the factory to
extract the mixed juice sugar from the raw material which is the sugar cane. On the second
and fifth week of the OJT the trainee was assigned here.
The milling of sugar cane produces raw sugar (brown sugar) and also by-products
such as molasses which is used as livestock feed additive and also to produce ethanol. The
operational manager of HISUMCO, Inc. are able to operate the sugar milling operations in
a cost effective manner. In addition, the mills generate their own electricity by burning
bagasse – the fibrous material leftover from crushed sugarcane. Excess electricity not
required by the milling operations is sold to the local electricity grid. HSIMCO, Inc. has
been a supplier of industrial ethanol for over 40 years. HISUMCO, Inc. also produces
fertilizer.
Figure 3.3.2a. Dismantling Turbine who Drive the 2nd Set Cane Crusher
33
Steam Turbine are considered as the heart of the Power Plant, because this is the
device which converts the thermal energy from steam to mechanical energy more precisely
as the rotational energy of the rotors or series of such rotors which eventually absorbs the
steam energy by virtue of its rotations which is the most vital component of a steam turbine.
HISUMCO, Inc. using impulse steam turbine which means there is no change in
the pressure of the steam as it passes through the moving blades. There is change only in
the velocity of the steam flow. This turbine has a capacity of 6500 revolution per minute
which is enough to drive the 2nd set cane crusher. During the repair season this was
dismantled to check if there are abnormalities in the system and the student trainee was
part of the activity. Loosen and tighten the bolts and draining the oil was done by the
student trainee.
Figure 3.3.2b. Assembling Turbine who Drive the 2nd Set Cane Crusher
34
After checking and fixed up all abnormalities in the system this was assembled as shown
in the Figure 3.3.2b. This was done almost 16 working days.
Par valve is a device that
distributes the lubrication oil equally
to the cane crusher gear box. Student
trainee was permitted to do the job by
cleaning the par valve.
Figure 3.3.3 Cleaning Par valve
3.3.3 Depart of Maintenance
The department of maintenance is headed by Superintendent Engr. Allan Niez and
assisted by his four supervisors, Engr. Reymund Lapezeros, Engr. Robert Castro, Engr.
Dinnes Ferales Jr. and Engr. McKinly Nahini. Maintenance officers they are the in-charge
to handle, to care and to control all equipment used in the factory. Among the three
departments where the trainee assigned the officers of the maintenance was the busiest
during the repair season because they were the one who do the monitoring and checking of
all equipment in the factory; in the boiler section, mill section, boiling house and in the
refinery area. The operational manager was targeting that the repair season would be done
within five months so that the season start again. Hence, the officer of the maintenance
doubled their time to do their task.
35
On the third and sixth week of the OJT the trainee was assigned to this department.
The activity assigned to the trainee was almost the same with his assignment in mill section.
This was because the supervising officer of the trainee was assigned at the mill section.
The following are some activities that the student trainee was part of.
The trainee assisted the mechanic in
dismantling the steam turbine which drive
the 2nd set cane knives. Loosening the bolt,
draining the coolant oil, cleaning the bolts
and nuts were done by trainee.
Figure 3.3.3a Dismantling Turbine
After dismantling the turbine
the student trainee also assisted the mechanic
in measuring the clearanance between the
shaft and the babbit bearing. The acceptable
clearance is 0.005 to 0.006 inch.

Figure 3.3.3a Measuring the Clearance
36
While the equipment were in standby mode
temporarilly, a lubrication oil was applied to avoid
corrosion and so to maintain the great performance
of the equipment. The trainee put a lubrication oil
to the bearings and after that, he rotated the shaft
of the machine manually.

Figure 3.3.3c Bearing Housing
Cane crusher is mainly made of three grooved
rollers suspended on journal bearings. They are
arranged triangularly with two rollers each
which are placed below a top roller. A minimum
clearance is maintained between the grooves when
the top and lower rollers are in meshed position. The
trainee was clean the groove of the cane crusher.

Figure 3.3.3d Cane Crusher Roller
37
3.4 Learnings of the Student Trainee
The On-the-Job Training in Hideco Sugar Milling Company, Inc. has left
remarkable experiences and learnings to the trainee. These learnings are not only about
academic but also about the social and physical aspects of the trainee. All of these
experiences have helped the trainee grow in his field of expertise.
In more than month of training, the trainee was exposed to the different actual work
in HISUMCO, Inc. in which he became familiar with the equipment they used as well as
its parts and functions. Also, he has learned to become more responsible, hard-working,
and his time management skill has developed. He learned that every task assigned to him
should be done correctly and should be finished on time.
During his OJT, the terms that the trainee learned in school, especially those related
to Mechanical Engineering were used in the company where he was conducting his
training. Thus, the trainee learned to appreciate even the simplest lessons studied in school
as well as the importance of theories and formulas. He has also realized that everything
that was taught in school is an important tool that can be used in his future career.
Furthermore, the trainee also has developed his sociability skills. He has learned
how to deal with different personalities and how to cope up with them and with the
environment. He was given the chance to get acquainted with the employees of HISUMCO,
Inc. either professional or not. Being with them is a pleasure because they are the ones who
kept on encouraging and motivating the trainee to study hard and to do his best always in
every task that he`s going to do. And from them, the trainee has learned the importance of
following instructions, accept and admit failures and learn from them.
38
After the training, the trainee realized that OJT is not just a requirement to be
completed but an opportunity to show the skills, knowledge, and talents that he have and
also an opportunity to experience the feeling of being a professional.
This remarkable training will not be as remarkable as it is without the people who
helped the trainee during the training. One of these people that the trainee will never forget
is his Training Manager who challenged not just his skills and abilities but also his patience.
His Training Manager is a kind of person who wants everything to be done right away and
correctly. He doesn’t like one who has doubts on a task that is done. Because of this, the
trainee was always nervous whenever his Training Manager roamed around the factory
especially during the working hours. But because of that kind of Training Manager, the
trainee became more confident to do what he know is right, without doubts in it. Another
person that the trainee has learned something from is the Turbine Mechanic in the mill
section. Whenever he asks him to do a particular task, he always keeps on saying that the
trainee should do things slowly but surely. He never pressured the trainee to make haste in
doing the tasks that he has given to the trainee. Generally, all of the people that the trainee
has worked with during his OJT are all very inspiring. All of them left a piece of advice to
the trainee that he will surely keep in his mind and in his heart for the rest of his life.
The trainee really had a very meaningful and memorable OJT at HISUMCO, Inc.
Though he already finished working there as a trainee, he is looking forward to working
with them, not as a trainee anymore, but as an engineer, SOMEDAY.
39
3.5 Problems Encountered
Throughout the duration of the OJT, there are some problems that being
encountered by the student trainee both in the office and field. Each problem cannot be
predicted but it can be eliminated if it is being managed properly. The following problems
with corresponding proposed solution are listed below.
1. Workers not wearing proper Personal Protective Equipment (PPE). Wearing of PPE
should be strictly implemented in the workplace to avoid accident between workers.
2. Some workers are smoking in the working area. The Company’s rules and
regulations should be strictly implemented so that no worker can smoke in the
working area and that they cannot disturb other worker especially those who are not
smoking.
3. There are equipment that looks very old and is exposed on corrosion. The
management should maintain the cleanliness of the equipment in the factory because
the products they produce were consumed by the domestic people.
4. The company lacks raw materials because lot of cane plantation in Ormoc city and
Kanangga Leyte were damaged due to the Yolanda typhoon. The company should
invest a capital where the farmers can borrow money from them so that the farmers
can recover and can plant again more sugar cane.
40
CHAPTER IV
SUMMARY AND RECOMMENDATION
4.1 SUMMARY
The OJT was conducted at Hideco Sugar Milling Company, Inc. located at Brgy.
Montebello, Kananga, Leyte from April 20 to June 03, 2015. During the OJT, some
objectives were established. Specifically: (1) To apply the theories and computation
learned from school; (2) To familiarize the types of equipment in the field; (3) To
familiarize the parts and the operation of the boiler; (4) Socialize and interact with the real
professionals and meet people having different positions in the company; (5) To gain
practical knowledge and develop skills, work ethics, and professionalism.
To attain those objectives, student trainee was assigned in three departments of the
HISUMCO, the Department of Boiler, Department of Mill and Department of Maintenance
in order to gain more knowledge through hands-on and actual observation. In the
Department of Boiler, the on-the-job training were focused on familiarizing the parts and
the auxiliaries of the boiler, knowing the distribution of the steam generated to the factory
and knowing the operation of the boiler. In the Department of Mill, the on-the-job training
is focused on familiarizing the equipment in the factory, familiarizing the parts, functions
and the operation of the steam turbine and assisting the mechanic by dismantling the steam
turbine. In the Department of Maintenance, the on-the-job training were focused on
familiarizing the types of tools, bolts and nuts, assisting the mechanic in dismantling the
steam turbine, measuring the clearance between the bobbit bearing and the shaft using the
“plastigage”.
41
Through OJT, the application of knowledge learned in academe was applied and
developed. Student trainee gained additional knowledge in management, supervising or
monitoring, and dealing with other people which developed student trainee’s self-
confidence in facing the real world of mechanical engineering profession.
It is also very warm to the heart to know that you have accomplished something
and even warmer when there are people who are so proud of what you have done and the
trainee felt this feeling during the OJT. It inspired the trainee to be more determined and
competitive in everything that he did in his daily life as a student today and as a professional
someday.
This OJT is very helpful and will be very significant to the trainee as he continue
to take his journey as a fifth year student in the field of Mechanical Engineering. It really
gave a taste of the real world – a glimpse of what lies ahead after the graduation.
4.2 RECOMMENDATION
4.2.1 for the Company
1. The Safety Program of the company must be strictly implemented in the factory.
And the company must provide complete Personal Protective Equipment to every
worker.
2. The Rules and Regulation of the company must be strictly implemented in the
factory. The management should monitor the workers to determine who disobeyed
the policies implemented. The workers should follow the Rules and Regulation for
the betterment of the company.
42
3. The company should be responsible for maintaining the cleanliness of the
equipment used in the company.
4. The company should create a loan program with low interest to help farmers plant
more sugar cane so that the company can produce more sugar for domestic and
export trade.
5. The company should provide a delightful certificate of compilation to the student
trainee as a reward of their efforts and contributions to the company during the OJT
for the future use of the trainees and also that another student are willing to do
internship in the company.
4.2.2 For Future Trainees
1. Choose a company that can provide Mechanical Engineering related services.
Apply as early as possible.
2. Be attentive and follow every instruction that is given by the supervisor. If you have
something to clarify, don’t hesitate to ask questions. Be honest, especially if you
don’t know certain things because as the saying goes, “To gain knowledge is to
confess ignorance”. Be flexible enough to perform activities. And don’t be late
because it will affect your performance.
3. Be patient; adapt the environment and the people around. Always have good
manners in dealing different people with different characteristics.
4. Be competitive, show your talents, skills and be a good model in the field of practice
as a future mechanical engineer.
43
CHAPTER V
LITERATURE CITED
Angeline Fate E.C. 2013. A Narrative Report in On-the-Job Training undertaken at

Commission on Audit Located at Commonwealth Avenue, Quezon City, Philippines 0880.
Colegio de San Gabriel Arcangel, Area E, Fatima V, City of San Jose del Monte, Bulacan.
Catherine A. April 2013. Characterizing Out-of-School Youth in Hindang, Leyte. Visayas

State University, Visca, Baybay City, Leyte.
HISUMCO Location Map. Retrieve 23 February 2016 from

https://www.google.com.ph/maps/search/location+map+of+hisumco/@11.295271,124.9
852221,8z/data=!3m1!4b1
Wilmar Sugar Mill. Retrieve 23 February 2016 from

file:///D:/Documents/mill%20section/Milling%20_%20Wilmar%20International.htm
Boiler Operation Manual. Retrieve 23 February 2016 from

https://www.google.com.ph/?gfe_rd=cr&ei=FrvLVo3dAu3C8ge_sKSgAg&gws_rd=ssl#q
=boiler+operation+manual
Boiler Parts and Auxiliaries Picture. Retrieve 23 February 2016 from

https://www.google.com.ph/search?q=boiler+parts+and+auxiliaries+picture&biw=136
6&bih=655&tbm=isch&tbo=u&source=univ&sa=X&ved=0ahUKEwjr28uj8IzLAhVFnq
YKHcjMAiEQsAQIHA
Key Components and Parts of Boilers.Retrieve23 February 2016 from

https://www.google.com.ph/search?q=Key+Components+and+Parts+of+Boilers&biw=
1366&bih=655&source=lnms&tbm=isch&sa=X&ved=0ahUKEwidzdum8YzLAhWCIKY
KHeMHAkMQ_AUIBigB
Cane Crusher Roller Definition. Retrieve 23 February 2016 from

http://www.academia.edu/4173898/Comparative_study_on_cane_cutter_juice_expeller_
and_roller_model_Sugarcane_juice_extraction_systems
Wikipedia. Retrieve 23 February 2016 from

http://en.wikipedia.org/wiki/education
44
APENDICES
45
Appendix A. Recommendation Letter
46
Appendix B. Application Letter
47
Appendix C. Resume
48
Appendix D. Confirmation Letter
49
Appendix E. Daily Accomplishment Report
Daily Accomplishment Report
Student Trainee: Fernando D. Siervo

Company: Hideco Sugar Milling Company
Department: Department of Boiler
DAILY WORK ACTIVITIES
WEEK 1
NO. OF
DAY DATE DAILY ACCOMPLISHMENT WORKING
HOURS
 Reviewed the “Rankine Cycle” and
the major parts of the boiler
Monday 04-20-15  Toured the department of boiler 8
guided by Engr. Ryan Cabilin
 Familiarized the equipment and the
parts of the boiler
Tuesday 04-21-15  Read the capacity of the motor and 8
the feed water pumps
 Cleaned the boiler water tube assisted
Wednesday 04-22-15 by Mr. Rey 8
 Thrown the ash in the boiler’s furnace
 Entered in the furnace of the boiler
Thursday 04-23-15 and counted the number of cylinders 8
of the water wall
 Familiarized the piping system in the
Friday 04-24-15 boiler department 8
TOTAL NO. OF HOURS: 40

Certified by:
Manager/Supervisor/OIC
50

Department: Department of Mill
WEEK 2
NO. OF
HOURS
 Toured the mill department guided by
Engr. Jovani
Monday 04-27-15  Familiarized the 8
equipment/machineries and its parts
in the mill section
 Observed the mechanic who cleaned
the steam chest of the steam turbine
Tuesday 04-28-15  Cleaned the par valve and 8
familiarized its part
 Assisted Mr. Toto cleaning and
Wednesday 04-29-15 putting lubrication oil to the ICC 8
(integrated chain conveyor)
 Continued cleaning and putting
Thursday 04-30-15 lubrication oil into ICC (integrated 8
chain conveyor)
Friday 05-01-15 “HOLLIDAY”
Certified by:
51

Department: Department of Maintenance
WEEK 3
NO. OF
HOURS
 Assisted Mr. Rey in dismantling the
Monday 05-0415 speed reducer in the second set cane 8
knives
 Continued assisting Mr. Rey in
dismantling the speed reducer in the
second set cane knives
Tuesday 05-05-15  Measured the clearance of the babbit 8
bearing
 Operated the chain black
 Drained the lubrication oil
 Continued assisting Mr. Rey in setting
the babbit bearing
 Operated the chain black
Wednesday 05-06-15  Counted the number of teeth of the 8
driver gear and the driven gear that
drives the cane knives
 Familiarized the types of tools, bolts,
Thursday 05-07-15 and also the parts of the steam turbine 8
 Cleaned the bolts and nuts
Friday 05-08-15  Continued Cleaning the bolts and nuts 8
Certified by:
52

WEEK 4
NO. OF
DAILY ACCOMPLISHMENT
DAY DATE WORKING
HOURS
 Entered in to the deaerator and
measured the diameter of the water
inlet
Monday 05-11-15  Computed the required compression of 8
the spring given the applied pressure,
20 psi.
 Thrown the ash
 Helped Engr. Cabelin checked the
Tuesday 05-12-15 alignment of the head shaft in the 8
bagasse feeder conveyor
 Measured the diameter of suction and

discharged the feed water pump
Wednesday 05-13-15  Computed the total dynamic head of 8
the pump
Thursday 05-14-15 ABSENT --

Friday 05-15-15 ABSENT --
Certified by:
53

Department: Department of Mill
WEEK 5
NO. OF
HOURS
 Helped Mr. Alex in dismantling the
steam turbine no. 2
Monday 05-18-15  Processed the withdrawal slip of the 8
materials needed
 Continued assisting Mr. Alex in
Tuesday 05-19-15 dismantling the turbine no. 2 8
dismantling the steam turbine no. 2
Wednesday 05-20-15  Processed the withdrawal slip of the 8
materials needed
 Assisted Mr. Alex in assembling the
Thursday 05-21-15 turbine no. 2 8

Friday 05-22-15 assembling the steam turbine no. 2 8
 Cleaned the tools
Certified by:
54
Department: Department of Maintenance
WEEK 6
NO. OF
HOURS
 Rotated manually the pumps in the
refinery
Monday 05-25-15  Assisted Mr. Rey in dismantling the 8
steam turbine in the 2nd set cane knives
Tuesday 05-26-15 dismantling the steam turbine in the 8
cane knives
dismantling the steam turbine in the
cane knives
Wednesday 05-27-15  Measured the clearance between the 8
shaft of the turbine and the babbit
bearing
 Operated the lifting ratchet
 Assisted Mr. Rey in pilling the side of
Thursday 05-28-15 the babbit bearing. Processed the 8
withdrawal slip of the materials
needed
 Continued assisting Mr. Rey in pilling
Friday 05-29-15 the side of the babbit bearing 8
 Cleaned the tools and the working area
Certified by:
55

WEEK 7
NO. OF
HOURS
Monday 06-01-15  Assisted the mason inside the furnace 8
 Continued assisting the mason inside
Tuesday 06-02-15 the furnace 8
 Continued assisting the mason inside

Wednesday 06-03-15 the furnace 8
Certified by:
56
Appendix F. Company`s Daily Time Record Sheet
57
Continuation of Appendix F
58
Appendix G. Weekly Activity Report
59
Appendix H. Certificate of Completion
60

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ON-THE-JOB TRAINING AT HIDECO SUGAR MILLING COMPANY, INC.

MONTEBELLO, KANANGA, LEYTE

An On-the-Job Training Manuscript

The undergraduate On-the-Job Training manuscript attached hereto entitled “ON-

THE-JOB TRAINING AT HIDECO SUGAR MILLING COMPANY,

MONTEBELLO, KANANGA, LEYTE prepared and submitted by FERNANDO

DUEÑAS SIERVO in partial fulfillment of the requirements for the degree of

BACHELOR OF SCIENCE IN MECHANICAL ENGINEERING is hereby accepted.

ENGR. RAMIL L. LAURON

degree BACHELOR OF SCIENCE IN MECHANICAL ENGINEERING.

ENGR. RAMIL L. LAURON

To my brothers: Jeffrey and Jomar, to my sisters: Adelina and Jullie Ann, to my

To the university where I am studying, Visayas State University, where I am

continuously growing as a Bachelor of Science in Mechanical Engineering student.

motivating me to study harder for me to have a better future.

contributed to my growth as a human being. I thank them so much.

able to finish this training without any conflict.

Thank You Very much!!!..

I wholeheartedly dedicate this

On-the-Job Training manuscript to my mother Amelia, my brothers Jomar and Jeffrey,

my sisters Julie Ann and Adelina, my future wife Catherine and

my baby Prince Nathan,

to all my instructors especially to Engr. Ramil L. Lauron,

to the Hideco Sugar Milling Company officials,

to my friends and co-trainees and above all,

to our Almighty God.

ACKNOWLEDGEMENT ………………………………………………….. iii

TABLE OF CONTENTS …………………………………………………. vi

LIST OF FIGURES ………………………………………………………… viii

1.1 Importance of On-the-Job Training ………………………… 1

1.1 Objective of On-the-Job Training ………………………….. 3

1.2 Time and Place of On-the-Job Training ……………………. 3

1.3 Scope and Limitations of the On-the-Job Training ………… 3

CHAPTER 2. WORK ACTIVITIES

2.1 Application Process ………………………………………… 4

2.2 Schedule of Activities ……………………………………… 5

3.1 THE HEDICO SUGAR MILLING COMPANY, INC

3.1.1 Company Background …………………………….. 7

3.1.2 Company Mission and Vision …………………….. 8

3.1.3 Company Policies …………………………………. 8

3.1.4 Company’s Location Map ………………………… 9

3.2 Practical Experiences

3.2.1 Boiler Department ………………………………… 12

3.2.2 Bioler Working Principle …………………………. 13

3.2.3 Steam Distribution ………………………………… 15

3.2.4 HISUMCO’s Boiler Operation …………………… 15

3.2.4.1 Starting up the Boiler …………………….. 17

3.2.4.2 HISUMCO’S Boiler Shut Down ………… 22

3.2.5 Key Components and Parts of Boilers …….. 24

3.3 HISUMCO’S REPAIR SEASON

3.3.1 Boiler Section ……………………………………… 31

3.3.2 Mill Section ……………………………………….. 33

3.3.3 Maintenance Section ………………………………. 35

3.4 Learnings of the Student Trainee …………………………… 38

3.5 Problems Encountered ……………………………………… 40

CHAPTER 4. SUMMARY and RECOMMENDATION

4.1 Summary ……………………………………………………. 41

4.2 Recommendation …….………….. ………………………… 42

4.2.1 For the Company ………………………………… 42

4.2.2 For the Future Trainees ………………………….. 43

CHAPTER 5. LITERATURE CITED 44

FIGURE FIGURE TITLE PAGE

2 Location map of Hedico Sugar Milling Company, Inc. Montebello,