TECHNICAL REPORT

ON

STUDENTS’ INDUSTRIAL WORK EXPERIENCE SCHEME

AT
KINGSKID CONCEPT LIMITED,
Nigerian National Petroleum Company Limited (NNPC)

BY

OLUDADE EMMANUEL OLUTAYO

18CM024430

DEPARTMENT OF MECHANICAL ENGINEERING

COLLEGE OF ENGINEERING

30th September 2022

Contents

1
Table Of Figures

2
ABSTRACT
This report covers an extensive review of experience gained, the skills
acquired, and the application of knowledge gained from my lecturers during
the course of the Student Industrial Work Experience Scheme (SIWES). I
was at Kingskid Concept Limited located at Plot 1026 Ladoke Akintola
Boulevard Garki,Abuja Nigeria, from 4th April 2022 to 3rd June 2022 then I
transitioned to the Nigerian National Petroleum Company Limited
(NNPC) at Central Business District Herbert Macaulay Way P.M.B 190
Garki, Abuja Nigeria from the 6th of June 2022 to 31st of August 2022.

The nature of the work done by me includes observation as the

construction of the shore protection was carried out.At Nigerian National
Petroleum Company Limited (NNPC) I was involved in reinstallation of the
cradles, pumps, Heat Ventilation and Air Conditioning(HVAC) system,
Powerplant and the elevators.The report strictly covers the activities carried
out by me and observations i made on site, engine rooms.

This technical report provides insight on the operation of a power

plant,Supply, Installation, Testing, Commissioning(SITC) and reinstallation
of cradles,the applicability of the knowledge gained from this experience
into real-life situations, and the exposure to the company's culture. It also
highlights some of the challenges encountered and how I overcame them
during the period of attachment. A few recommendations which can
improve the benefit of this program.

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ACKNOWLEDGEMENT
The opportunity to work at Kingskid concept limited exciting, learning
experience for me. During my internship, I learned a few beneficiary things
about construction and the importance of a mechanical engineer on a
construction site

THe opportunity to be a part of the Nigerian National Petroleum Company

Limited (NNPC) was something I couldn't let pass me by. At NNPC I learnt
on the operations and maintenance of lifts, pumps, chillers and generators.

I have to thank both KingsKid concept and Nigerian National Petroleum

Company Limited(NNPC) for giving me this opportunity to learn and be
impacted on during the period of Student Industrial Work Experience
Scheme (SIWES).

I am grateful to God for keeping me alive to this day and the successful
completion of my SIWES program.

I am grateful to my supervisors, Engr. Esi Chris, Engr. Mustapha, Engr.

Oluwagbenga for their guidance, teachings and mentorship during the
course of this work experience program.

I appreciate my parents Mr/Mrs. Oludade for their support during this period
financially, morally, academically etc.

Further on, I want to thank friends such as Roy, Yilkudi Ritji, Dorathy etc.,
and fellow interns; owolabi israel, john mamza, etc., for their moral support
as they made this learning period joyful and efficient.

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1. CHAPTER ONE
1.1 SIWES Letter Collection, Submission, Response, Recruitment and
Acceptance to the Companies

Student’s Industrial Work Experience Scheme is a program set up to permit

and prepare students of Universities, Polytechnics, and much more the
opportunity to experience what they are most likely to face after graduation.
Before receiving my acceptance letter, I had enquired about the availability
to carry out an internship at three different companies by name as
Coscharis Motors, Nigerian National Petroleum Company Limited and
Kingskid Concept Limited; I didn't receive a feedback from Nigerian
National Petroleum Company Limited (NNPC) until the 3rd week of May. I
had arrived home and submitted my letters to the various companies to be
later interviewed. The offer of kingskid concept limited came but I was
hesitant to start and waited for a week to get a reply from NNPC before
beginning anywhere else.The managing director at kingskid concept gave
me a letter telling me to start on Monday 4th of April 2022. I resumed and
was placed in the engineering department, put through some lectures
concerning safety and was taught on basic operations of the service
vehicles.

1.2 About and Location of the Companies

I worked at Kingskid concept limited, the head office located at Plot 1026
Ladoke Akintola Boulevard Garki,Abuja Nigeria, from 4th April 2022 to 3rd
June 2022 then I transitioned to the Nigerian National Petroleum Company
Limited (NNPC) at Central Business District Herbert Macaulay Way P.M.B
190 Garki, Abuja Nigeria. Kingskid is a private unlimited company that is
dedicated to its customers, society, and partners globally. It has been
establishing its authority majorly within Nigeria picking up huge government
contracts. Its subsidiaries are just as huge and well known within Nigeria. It
has been majoring in construction for the past 10 years. It has invested
heavily towards the development of Nigeria to become the giant of Africa.
Kingskid Concept was founded in 1999; it is a civil engineering company.
The Nigerian National Petroleum Company Limited is a for profit oil

5
corporation in Nigeria.NNPC Limited is a dynamic global energy company
with businesses and operations across the entire spectrum of the energy
value chain.We are focused on energy transition while ensuring domestic
energy security. Vision:To be the dynamic global energy company of
choice.Mission:Reliably delivering energy while continuously creating value
for all stakeholders.

1.3 Submission of Acceptance Letter and SPF form

I had begun my Internship, and within the first two weeks, I hadnt located
the nearest ITF office. By the time I had my SPF form filled by my IT
supervisor and me and stamped before going to submit the form, It wasnt
accepted; I was unable to receive my acceptance letter in time.i prepared
two separate SPF since i went to two companies. I sent my letter to SIWES
soon after I wasn't notified at all on whether they had received my letter.

Figure 1: Acceptance Letter to Kingskid Concept Limited

6
Figure 2: Acceptance Letter to Nigerian National Petroleum Company
Limited

7
1.4 Commencement of Internship

As I began at Kingskid concept, I was stationed at the engineering

department for the duration of my stay with the company.I learned and used
specific tools such as gloves, knife safety goggles this was during the
cutting of the geotextile fabric and during the formation of gabion boxes. At
Nigerian National Petroleum Company Limited, I was stationed at the
utilities and maintenance department where I learnt on cradled elevators,
pumps and even water cooled chillers. I was opportuned to control a crane
and I also got to enter into the basket of the cradle system from the roof of
the building.I was present when the motors of the cradles were
disassembled and new ones were installed.I observed as float switch with
the roof was replaced.I visited the lift engine room a couple of times to
understand its operation.I watched as the engineers replaced the guides
within the lift and asked detailed questions on everything been done during
the replacement.I also visited the ngineerin and Technological Department
during their lectures on ASPEN: which is an app used in the calculation of
crude oil and its related products and so much more. I spent a good
amount of time with the senior Heat Ventilation and Air
Conditioning(HVAC)in the Central Building Management System room. I
was shown so many components within and connected to the different
aspects that concerned the utilities and maintenance department and how
they operate. The industry-based supervisors were constantly checking up
on me as he placed me in different departments to ensure I was learning
and coping well with the work, and asked me questions ensuring that I
understood the action being carried out during work. My supervisor from
Covenant University had visited my workplace inspecting the facilities
available and grading my performance here at Nigerian National Petroleum
Company Limited. He discussed it with my company-based supervisor.

8
Figure 3: KINGSKID CONCEPT LIMITED

Figure 4: Nigerian National Petroleum Company Limited

9
 2. CHAPTER TWO

2.1 Facilities and equipment available

The Nigerian National Petroleum Company (NNPC) Limited is the state oil
corporation which was established on April 1, 1977. In addition to its
exploration activities, the Corporation was given powers and operational
interests in refining, petrochemicals and products transportation as well as
marketing.Within the NNPC Towers I was under the division of Group
Admin Services (GAS).
The activities of the division are shared among six (6) sections namely:
● Office and Management Services (O&MS)
● Logistics and Fleet Management (L&FM)
● Valuation and Acquisition (V&A)
● Headquarters Purchasing Services (HPS)
● Utilities and Maintenance (U&M)
In this chapter I will discuss on the facilities controlled and managed by the
Utilities and Maintenance (U&M) department and the knowledge gained
during my stay with the company include the following;

2.1.1 The Heat Ventilation and Air Conditioning (HVAC) System

It is a central air conditioning system, and works to provide cooling through
the following components:the Chillers, Air Handling Unit (AHU’s), Pumps,
Pipings/Risers, Diffusers, Building Management System (BMS).An
industrial chiller is a refrigeration system used to lower the temperature of
machinery, industrial spaces, and process fluids by removing heat from the
system and transferring it somewhere else.
Within the NNPC Towers there are three(3) chillers in Block C and B and
four(4) chillers in Block A and D.
Chillers work using either a “Vapor compression cycle”, or an “Absorption
cycle”.Chillers consist of four basic components; an evaporator, a
compressor, a condenser, and an expansion unit. Every chiller system
contains a refrigerant.The process starts with a low-pressure refrigerant
entering the evaporator. Inside the evaporator, the refrigerant is heated,
causing it to undergo a phase change into a gas. The gaseous refrigerant
goes into the compressor which increases its pressure.The high-pressure

10
refrigerant goes to the condenser which rejects the heat using cooling
water from a cooling tower or air from the surroundings, condensing it into
a high-pressure liquid. The condensed refrigerant then goes to the
expansion unit which has a valve that acts as a metering device to limit the
flow of refrigerant in the system.
Consequently, this lowers the pressure of the refrigerant and begins the
cooling process again. The entire process is known as the refrigeration
cycle.A chiller provides consistent temperature and pressure to your
industrial process. Eliminating temperature and pressure variables
simplifies the process development and optimization, ensuring the highest
quality product. Instead of a wasteful, single-pass-through system, a chiller
recirculates the cooling water.

This type of chiller needs cooling water to reject the heat from the building.
The chiller produces chilled water and pushes this around the building to
Air Handling Units (AHU's) and Fan Coil Units (FCU's).These units circulate
air around the local space as well as the building. The Air Handling unit is
an equipment used to recondition and circulate air as part of an HVAC
system, and are located on every floor in Nigerian National Petroleum
Company (NNPC) TOWERS. It achieves this using the process shown
below

Figure 5: Labeled Parts of the AHU

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Functions of the AHU Components

1. Grill: The incoming fresh air from the surrounding is first filtered here,
to remove any impurity.
2. Dampers: This component regulates the amount of fresh and return
air in the AHU. It is connected to a motorized actuator, that help it
achieve this function.
3. Filters: They can be either panel or bag filters, and they aid in further
purifying the incoming fresh air. They usually have an Air Differential
Pressure Switch (ADPS), attached to them. The ADPS generates an
alarm effect in the Building Management System, signaling that the
filters are due to be cleaned (when the pressure across them is high).
4. Cooling Coil: connected to the chiller system. For the both coils,
either the chilled/hot water passes against gravity to provide for
sufficient time for heat exchange, thereby increasing the system
efficiency.
5. Heating Coil: connected to the boiler/heating system. A frost
temperature sensor activates this coil when the air temperature goes
below 5 degrees.
6. Blower: A fan, connected through a belt and pulley system to an
induction motor. It functions to enable air flow. It is connected to a
Variable frequency/speed drive (VFD/VSD), automated and goes to
the Building Management System.
Water cooled chillers are typically used on large commercial properties i.e
NNPC Towers, with high cooling loads, you can tell if a building has a water
cooled chiller because it will need cooling towers which are typically on the
roof. There will usually be more than 1 chiller and cooling tower, its not
uncommon to have at least 2 or 3 or even more just for redundancy as well
as variations in cooling demand.
The chilled water pump is a part of the overall Heat Ventilation and Air
Conditioning (HVAC) system.The chilled water pump is used to circulate
chilled water in a closed system. The chilled water pump circulates return
chilled water from the air handling units & fan coil units back to the chiller.
The chiller then cools the chilled water and the chilled water is then
supplied back to the air handling units and fan coil units.
Centrifugal pump is the type used within the Towers.Centrifugal pumps
operate on the principle of "centrifugal force", which is the conversion of

12
rotational kinetic energy imparted by rotating impellers onto the liquid to
produce a flow rate (kinetic energy) at a certain pressure (pressure
energy). Fluid enters the pump at the center or eye of the impeller. The
rotating impellers then push the fluid to the outer edges, imparting a flow
rate and pressure.
The chilled water pump must be sized properly to circulate the correct
amount of flow at the correct pressure in order to achieve proper cooling
within the building. If there is insufficient flow and pressure, then there will
not be enough cooling and the building may get hot during periods of high
cooling load. If there is too much pressure and flow, then the electrical
system will be unnecessarily burdened and if there is no speed control,
then electricity may be wasted due to excess pumping.The centrifugal
pump has a suction side, where low pressure is created by high velocity
backward curved impellers. It also has a discharge end, with increasing
area, that helps convert K.E into Pressure energy. It works using the
BERNOULLI’S PRINCIPLE.There are TWO pumps, one pump duty, the
other pump standby for one air-cooled chiller, while this pump circulates the
water in the chilled water network.

Figure 6: Pumps Within The NNPC Towers

Automatic Water Makeup
The tank is used as storage to cover peak loads or in situations when a
surge in demand exceeds the capacity of the cooling system.
If the chilled-water cooling system is expected to lose water during normal
operations such as mold changeover or hose-changing, an automatic water
makeup system should be installed or ordered from the factory as an
option.

13
The automatic makeup system must include a water-pressure regulator
and pressure gauge. Be aware that if there is a tank installed inside the
chiller, it will have a specified maximum design pressure rating. Do not
discharge city water, which can be as high as 60 to 80 psig, directly into the
chiller without first confirming the pressure rating of the chiller's tank.
Instant pressurization could rupture the tank. Closed tanks in chillers
always should have a relief valve for this purpose.

Figure 7 : Make-up tank within the NNPC Towers

When air blows directly out of your ductwork and through a register or
grille, it is either being directly pushed out or down. Once installed, an
HVAC diffuser will cause the air to spread out evenly in multiple directions,
which allows for even distribution. Plus, a diffuser is also beneficial for the
reduction of noise with a properly designed system
HVAC diffusers not only improve the effectiveness and efficiency of your
cooling and heating equipment by spreading air more effectively in a given
room, but they also have an attractive appearance, too. These devices
come in round, square, rectangular, and linear designs.

What is a Building Management System?

Building Management Systems (BMS) control and monitor the large energy
consuming systems within a building, such as HVAC, lighting, fire and
security systems. The aim of a BMS is to maintain occupant comfort and
ensure occupant safety, whilst delivering energy efficiency and lower
operating costs. The correct operation of a BMS is essential for optimal
building performance and offers the most cost effective option to achieve
energy savings in typical buildings.HVAC systems are made up of various
items of equipment including boilers for heating, chillers for cooling, air
handling systems for air-conditioning and a range of ancillary components

14
such as pumps and fans. The BMS controls the operation of the various
HVAC elements based on information received from sensors which monitor
key parameters such as temperature, relative humidity, carbon dioxide
levels (as a measure of indoor air quality), system pressure and occupancy.
Locations Within The Nigerian National Petroleum Company (NNPC)
Limited Tower
• The BMS is situated in the Service floor of each block.
• There is a Central BMS in the Service Floor of Block A.
Some of its functions include;
• Alarm management
• Trend management:providing data for on-charging occupants for
after-hours use and for energy consumption where the tenancy power
supplies are provided by the landlord
• Time schedule:providing useful data for scheduling service visits by
maintenance contractors.

Figure 8 : The Building Management System

Tabulated below is a summary of the cooling system equipment, as
installed within th NNPC Towers:

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Safety Precautions
The following safety precautions should be adhered to;
● Operators should always use their Personal Protective Equipment
(PPE), such as: Helmets, Safety boots, reflective jackets, safety
google, protective gloves.
● Proper job hazard analysis (JHA) should be conducted.
● Restriction of movement in the condoned area of site.
● Install and maintain carbon monoxide and smoke detectors.
● Turn off main circuit breakers beforehand. This eliminates the threat
of electrocution, and prevents any expensive equipment from being
damaged as well.
● Schedule annual professional maintenance.
2.1.2 The Lift and Lift Engine Room
An elevator, also called lift, is a car that moves in a vertical shaft to
transport passengers or freight between the levels of a multistory building.
Two Types - Traction & Hydraulic lifts.Most modern elevators are traction
elevators - propelled by electric motors, with the aid of a counterweight,
through a system of cables and sheaves (pulleys).Electric elevators start to
move through the signal and command comes from the control panel.This
elevator moves by friction of the steel rope with a traction pulley through
the signal and command from the control panel.
It is a mechanism that moves the elevator up, down and horizontal. Lift car
works with a counterweight. Lift car and the counterweight are nearly the
same weight. Thus energy saving is ensured. This kind of traction machine
is called a friction traction elevator.

16
There are twenty-two(22) lifts currently in the Nigerian National Petroleum
Company Limited(NNPC)Towers with seventeen(17) functioning
appropriately.These elevators were installed by OTIS Elevator Company.

Figure 9: Elevator Locations Within The NNPC Towers

Automatic Lifts, Automatic Elevators
There are panels opening both sides at landing and cabin doors which
open to the left-right and center. These panels work automatically.
The passenger calls the lift where he is. When the lift arrives to the
intended floor the doors open automatically. Automatic doors close when
the passenger gets inside the elevator. The user pushes the button where
he/she would like to go. In a short time the lifts move. The indicator shows
the next passengers where the lift is going on through the lights on the
cabin operating panel.
Thus many passengers benefit from the elevator. When there is no call to
the lift, it automatically switches off itself until a new call.
Thanks to the photocell, if there is anyone in front of the door it
automatically opens the doors. Thus the automatic door lifts are safer and
are the one used within the NNPC Towers.
The key parts of an elevator are:
1. Car (metal box) that rises up and down.

17
 2. Counterweights that balance the cars (weight of car + 40%-50% of
weight it can carry).
3. An electric motor that hoists the cars up and down, including a
braking system.
4. Control Unit sends signal to the motor to move up/down when a
button is pressed in the lift (COP)
5. A system of strong metal cables and pulley’s running between the
cars and the motors.
6. Various safety systems to protect the passengers if a cable breaks.
Governors – speed regulating system
Car Buffer – protects people against malfunction of elevator control
system
Guide rails – safety
Some Parts of Elevator and Its Function
In this section of the report, I will tell you about the various parts of
elevators and their function.
Elevators have been around for many years. Let's take a closer look at
parts of elevators and its function.
● Speed Governors
The speed regulating system of elevators is known as the speed
governor.If the elevator runs more than the speed limit, the speed governor
controls the speed. It is usually attached to the bottom of the car and is also
known as governor rope.
● Electric Motor
In case the lift faces any serious condition, Electric Motors helps in
preventing it and provides a smooth functioning of lifts.
● Elevator Rails
Sliding up and down in the elevators is possible with the proper functioning
of Elevator Rails.
● Cabin
This is the main part of Elevator which is designed for the shipment of
goods and services or the passage of persons.
● Elevator Shaft
Lift cabin moves in this space. Depending upon the type of elevator, the
location of the shaft can be varied

18
 ● Doors
As normal doors, elevator doors are also meant for entry and exit. Elevator
door is of two types: Manual doors and Automatic doors.
Manual doors: These types of doors are opened with the help of a person
who wants to enter the lift.
Automatic doors: Automatic doors are the type of doors which are
automatically opened as it is powered by a door operator.
● Drive unit
Everything that works under electricity must have a motor attached for the
functioning. Drive unit is the part which contains a motor that drives the lift.
● Buffers
The buffer is an apparatus located at the bottom of elevator designed to
protect people. Buffers can stop a descending car by accumulating or
dissipating the kinetic energy of the car.
● Safety device
This is a mechanical device attached to the elevator for safety reasons. In
case the lift travels downward with a maximum speed or over the speed
limit, safety device can maintain a safety and secure traveling.

Add…..

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Figure 10: Labeled Parts of a Lift

The working principle of an elevator or lift is similar to the pulley system. A

pulley system has been used to draw water from wells - A bucket is
connected to a rope that passes throughout a wheel. The main difference
between these two are; pulley systems are operated manually whereas an
elevator uses sophisticated mechanisms for handling the elevator’s load.

As at March 2014, lift failures within the Towers had become very frequent.
Lifts were aged, thus posing safety and maintenance challenges. Major
components of the lifts had gone obsolete creating serious spares
challenges. Eight (8) out of the 22 lifts were completely non-functional,the
remaining 14 exhibited varying levels of epileptic availability. Therefore
there was a need for modernization of all the lifts within the NNPC Towers
which began with

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A. Replacement of:
● A/C Motor Generator and DC Machine drives sets (gear system
and pulley) with Compact Gearless A/C Machine drives
● Microprocessor-based control panels
● replacement of steel ropes with frictionless steel reinforced flat
belts (for the duplex lifts).
● All car sensors and detectors
● UPS Batteries, spares and accessories
B. Refurbishment of interior of 22 lift cars (including lighting, car operator
control panels and aesthetics).
C. Replacement of all car doors and landing doors for all lifts;
● Replacement of all 17 Duplex lifts car doors, inclusive of the
complete door mechanism.
● Replacement of all 271 Landing doors.
● Replacement of guide shoes with rollers for all 22 lifts.
● Recalibration of the speed governors for all 22 lifts.
● Installation of biometric access control for the Executive lifts.
● Recalibration of the speed governors for all 22 lifts.
● Installation of Car Operating Panel(COP) Screen Advert display
for all Duplex lifts

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2.1.3 The Pump Room

A water storage tank is a container for storage of water for domestic and
industrial uses. Water storage tanks are available in many shapes and
sizes. They can be vertical, horizontal, underground and potable, and can
be made from plastic, steel, fiberglass, stone or concrete. Water tank
leakage and corrosion as well as bacterial growth are threats to the tank.
What is a water booster pump?
A booster pump is a device that increases low water pressure and flow. It
provides the extra boost needed to bring your water pressure to the desired
level. A water booster pump provides pressure to move water from a
storage tank or throughout a whole house or commercial facility.
What causes low water pressure;Gravity, Distance from water source,
Low city water pressure, Additional water systems, Plumbing problems .A
booster pump boosts water pressure and, in many cases, improves the
flow rate. A booster pump works just like a fan. A fan has blades that spin
around to increase air movement, and a booster pump has an impeller
inside that increases water flow and pressure in the same fashion.
Booster pumps have an impeller that moves water that comes in through
the inlet and exits through the outlet. A motor makes the impellers spin.
Booster pumps differ according to how they suck water in and push it out.
Some water booster pumps use a spinning propeller, while others use an
oscillating diaphragm. Pumps with oscillating diaphragms propel water
using two oscillating or rotating plates— one with cups and one with
indentations. As the plates roll together, they compress the cups and force
the water out. As the plates roll open, more water is sucked in.
A flow meter (or a flow sensor) is an instrument that is used to indicate the
amount of liquid, gas, or vapor moving through a pipe or conduit by
measuring linear, non-linear, mass, or volumetric flow rates.The boiler
pressure gauge is usually located at the front of the boiler. It indicates the
pressure of the water leaving the boiler. The gauges are generally
calibrated in three sections that show when the pressure is too low, too
high, or correctly pressurized.Level switch:A level switch is a sensor that
detects the presence of liquids, powder, or granulated materials at a
specific location.(It is also referred to as level sensor) For example, when a
tank is supplied with liquid, it overflow.In order to prevent overflows, a level

22
switch is installed near the top of the tank. When the liquid touches the
level switch, it outputs a signal to keep the liquid from overflowing the tank.
(To detect that a tank is filled with material is referred to full detection, or
upper limit detection.) On the other hand, when the liquid level drops as the
liquid is discharged, a level switch is used to prevent completely draining
the tank. This is referred to as an empty detection or lower limit detection.
Operation On How Water Is Supplied Into Nigerian National Petroleum
Company (NNPC) Towers
The NNPC Towers water supply infrastructure consists of the following
components; Pipe Network, Boreholes, Storage Tanks, Pumps.
We have 6 in total; 4 Domestic Boreholes (1 per block) and 2 safety
Boreholes located within the premises of the Tower
Storage Tanks: 8 Domestic Water Tanks (2 per block), 4 Safety Tanks (1
per block), 1 extra Tank for the Designated Line, 4 Tanks supplying the
Chillers (1 per block).

Figure 11:Domestic Water Tanks at the 2nd basement and roof tops

Figure 12: Boreholes in Block A and B

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Figure 12: shows the distribution channel for water within the NNPC
Water is supplied in the NNPC Towers through a method known as
overhead tank distribution. In this method there's still an adequate supply
and pressure in the event of power failure.
There is a pressure reduction valve on the lower floor to prevent too much
static pressure.
There is a pressure booster system on the higher floors to create sufficient
pressure due to insufficient geometric height.
Advantages of the roof tanks
● Mature technology
● Space saving
● Only one main discharge from booster system to the overhead tank
● Less sensitive to electric fallouts
Disadvantages include
● Water is pumped passed where it is required
● Insufficient pressure at upper floors
● Excessive pressure at lower floors
● Pressure reduction valve has to be fitted
● There is need for high pressure gradient of paperwork
● Space requirement for overhead tank.

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Figure 13:Overhead Tank Distribution
The NNPC Towers has an average water consumption of 1,335m3
(1,335,000 Litres) Daily.
The Freshwater Pump
Freshwater pumps deliver water to fixtures onboard a boat. Pressurized
water systems make life more comfortable by providing water "on tap" for
dishwashing, showers and other applications. The complexity of installing
and maintaining one depends on the number of outlets and accessories
you choose.
Freshwater Tank: We think that rigid holding tanks are best, but flexible
tanks can work in an odd-shaped or inaccessible space. Tank size depends
on the space available and your needs (anywhere from one to ten gallons
per person per day might be consumed). Make sure your tank's deck fill
has a tight seal and that your tank's vent terminates the boat so your
drinking water supply won't be fouled by outside water.

25
Hose: Most pumps and fixtures are designed for 1/2" ID hose. Be sure the
hose you choose can handle 35–40psi and is made from FDA-approved
(nontoxic) materials. Hot-water hoses must be reinforced to withstand high
temperatures.
Strainer: Any electric pump should be protected by a strainer or in-line
filter. Water system and washdown pump manufacturers usually sell
strainers that can be attached upstream from their pumps.
Accumulator Tank: A sealed air chamber combined with a water reservoir
provides expansion volume to reduce pump cycling from minor pressure
changes and give a steady flow. Larger tanks can store enough water to
eliminate pump cycles when modest amounts of water are needed. Until a
few years ago, this was the last word for functional pressure water systems
aboard.
Municipal Water Inlet: By connecting a drinking-water-safe garden hose
between a municipal water inlet and a faucet on shore, you'll have a
continuous source of pressurized water at the dock without ever having to
fill the tank or operate the pump. To protect and isolate your pump and
accumulator tank from potentially damaging high pressure, install a
one-way check valve as shown in the diagram.
Faucet/Shower: Showers, whether in the head or out on the swimstep,
can greatly enhance your quality of life on board. Higher capacity pumps
with large accumulator tanks will provide the most home-like shower. When
adding an interior shower, it is necessary to have a shower sump so you
don't fill up your dry bilge with slimy water every time you bathe.
A check valve is a mechanical valve that only permits water flow in one
direction. It will also prevent city water pressure (which is higher than the
pump can handle) from going into the pump. Most diaphragm pumps have
check valves built-in.
A pressure switch opens the electrical circuit to a pump (and turns it off)
when the water in the system reaches a pre-set pressure, usually
35–60psi. It closes the circuit (and turns the pump back on) when the
pressure falls below that point. It is the device that makes on-demand
pumps function automatically.

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Maintenance Schedule

2.1.4 Fire Fighting System

The NNPC Towers stand at a height of 75m per block. The Towers have
over 1000 offices and meeting places where fire outbreaks can emanate at
any time. As such, the fire systems in the Towers wholistically cover the
following:
1. Fire alarm system:A fire alarm system typically detects smoke or fire
and warns a building’s occupants.it consists of;sound alarms,visual
alarms, smoke detectors, heat detectors,manual call out point etc.

Figure 14: Detectors and Manual Call-Out-Point

2. Water sprinkler system:Sprinkler System is an automatic system
designed to detect, control and eliminate fires and warn fire residents.
Installations of the system consist of a set of pumps (duty, jockey, and

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 standby), system water storage tank, main control valve set, sprinkler
head, flow-switches, pressure switches, flow pipe and valve.
The sprinkler pump set in the NNPC Towers has a diesel generator pump,
electric pump and a jockey in between them.
The sprinkler head consists of glass bulbs containing a liquid glycerine
solution that expands at a temperature of 68 Celsius (depending on the
type of liquid) and breaks the glass bulb and produces a water spray to fire.
As we know, water is a tool that can prevent fire. Continuous spray on the
surface of the fire and heat can reduce the temperature of the combustion
process and prevent the flame from spreading to the nearest space. There
is a metal cover on the top of the glass bulb to hold water from flowing out
through the sprinkler head.
The heat from the combustion process increases the room temperature
and causes the fluid in the bulb to expand. When the temperature rises to
68 degree Celsius (depending on the type of sprayer head), the glass bulb
will break and the metal cover will fall causing the water to flow out and
about the deflector plate to form a water spray.
When the flow switch detects the flow of water in the distribution pipes, the
signal will be sent to the alarm panel to sound the alarm warning bell and at
the same time, the pressure switch detects the pressure of the water
pressure and moves the jockey pump.
The ‘jockey’ pump will operate automatically to start up the electric pump
and also adjust the water pressure change in the pipe.
When the pressure is decreasing, the ‘duty’ pump will operate automatically
and the jockey pump will automatically stop.
When the fire is completely discharged, the flow of water in the pipeline will
be stopped by using the “butterfly” valve in the fire zone and the duty pump
will be discharged manually.
The system shall have a direct connection line to the nearest Fire Station.
Note that the sprinkler works to detect heat. At certain temperature
tolerances, the fluid in the tube will rupture until the sprinkler head releases
water. But the sprinkler releases less water. This is because the sprinkler is
enabled to extinguish a relatively small fire.
Also note that the function of the diesel generator pump is in case a fire
outbreak was caused due to an electric issue the diesel generator pump

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will startup instead of the electric pump to provide water flow at a higher
pressure to the system in order to put out a fire.

Figure 15: Basic Sprinkler System

Figure 16:Sprinkler Pump Motor

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 3. Automated gas extinguishing system:An automated gas extinguishing
system is preferred in locations where water extinguishing may
damage equipment or affect occupants’ health.

Figure 17:Labeled Automated gas extinguishing system

4. Portable fire extinguishers:Fire extinguishers are active fire protection
devices used in controlling small fires, typically in emergency
situations. They are usually located against a wall or on the floor in a
corner.

Figure 18: Fire Extinguishers

5. Fire hydrants and hose reels:Fire hydrants are connection points that
can be tapped for water supply. Hose reels are usually connected to
fire hydrants during active fire suppression. Where a building has
multiple floors, hose reels get water supply through dry risers.

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Figure 19: The Towers Hydrants and Hose reels
6. Fire fighting trucks:Fire fighting trucks are vehicles that transport
firefighters, fire fighting equipment and water to a fire incident
location. They also often support rescue operations for tall buildings.

Figure 20: Rapid Intervention Vehicle, Triple agent fire truck and
Rescue Truck with Turntable Ladder.

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Figure 21:Working Philosophy of the Towers’ Fire Fighting Systems
2.1.5 Power Systems
The NNPC towers is comprised of 4 towers occupying about 40000 square
meters.Blocks A & D have 15 floors each while Blocks B & C have 17 floors
each.It houses over 3000 occupants. Other major components include;
14Nos. HVAC Chillers, 6Nos. Boreholes, 4Nos. Fire sprinkler pumps,
22nos, Lifts, AHUs e.t.c All these facilities consume a lot of power.
An electric power system is a network of electrical components deployed
to generate, supply, transmit, and use electric power. The power system of
the NNPC towers includes the devices connected to the system like the
generator, transformer, distribution boards, circuit breakers etc.The power
demand of the NNPC towers is about 7 Megavolt Ampere(MVA), average
monthly power consumption of the NNPC towers is about 1,500,000 kWh.
Power is supplied to the NNPC Towers through the mains supply from the
Abuja Electricity Distribution Company (AEDC), the PERKINS Generator
and the WARTSILA PowerPlant.
WARTSILA POWER PLANT
There are four(4) generators in the wartsila power plant each with a
capacity of 4 MegaWatts.The average load used in the towers is about
5.5MegaWatts and during this time at least two of the four generators must
be switched on and working properly hand in hand. For this to happen the

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two generators must be synchronized. Synchronized generators must have
the same
★ frequency
★ output voltage
★ power factor
In the NNPC Towers the PowerPlant is started using the compressed
air.They are dual fired generators. Dual fuel generators are gaining
popularity due to their potential flexibility and reliability.Dual fuel generators
use two different types of fuel (most often diesel and natural gas) at the
same time. It usually cranks up on one type of fuel, and a governor built
into the system gradually adds the secondary fuel source until the optimal
mixture of the two fuels is achieved for efficient running.These fuels can be
mixed in different proportions or used alone, depending on the engine and
the situation. A dual fuel generator can be more eco-friendly.Natural gas
burns cleaner than diesel, so a mixed fuel can offer lower emissions than a
generator powered solely by diesel.Other potential benefits of a dual fuel
generator include the availability of natural gas. Most industrial businesses
already have a natural gas supply available nearby. This supply does not
need to be stored on site, which eliminates the maintenance and space
associated with large diesel fuel tanks. In the case of an emergency
situation, this natural gas will likely still be available, helping diesel stores
(which can be difficult to replace during emergencies) last longer. Natural
gas is also currently less expensive than diesel.Because natural gas burns
cleaner than diesel, less routine maintenance of oil and other generator
components is required.
There are different pipes with different colors in the dual fired powerplant
★ the brown pipe represents the diesel
★ Yellow represents the Compressed Natural Gas(CNG)
★ Blue represents air
★ Green represents the coolant or water

Figure 22: Different Pipes In The WARTSILA PowerPlant.

Besides its technical functions, the control room is a room in which the
power plant personnel spend a great deal of their time controlling all the
action that occurs within the generators. Control Panels are in the control

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room.Control panels are usually enclosed printed circuit boards with
connections to all peripheral devices in their area. The control panel
manages the peripheral devices and communicates between the host
computer and the peripheral devices.The control panels have the following
functions:
I. Consolidation of all connections to peripheral devices
II. Provision of power, as needed, to peripheral devices
III. Management of peripherals when communications to the host
computer are absent or when acting in a distributed manner
Figure 23: Starting Conditions For The WARTSILA Power Plant
Figure 24: The Control Room
I will be explaining and giving short notes on various components with the
power plant.Most peripheral devices connected to a control panel do not
have a lot of information to communicate. The device is either “on” or “off”
or “open” or “closed.” These devices (door contacts, requests to exit, door
lock, auxiliary outputs and inputs) may communicate with a simple dry
contact.
Auxiliary power is electric power that is provided by an alternate source i.e
the battery and that serves as backup for the primary power source(i.e the
generators) at the station main bus or prescribed sub-bus.The Electrical
Auxiliary Equipment comprises all the electrical systems needed to operate
and maintain the powerhouse.This includes; fuel pump, starting gear.
An offline unit provides electrical isolation between the primary power
source and the critical technical load whereas an online unit does
not.Circuit breakers have a switching capability for switching on and off any
kind of current up to the rated current, that is, load current and short-circuit
currents.A rectifier is an electrical device that converts alternating current,
which periodically reverses direction, to direct current, which flows in only
one direction. The reverse operation is performed by the inverter.ncoming
and outgoing feeders in switchgear are equipped with circuit-breakers and
disconnection and earthing switches. Current and voltage transformers for
the connection of protection and measurements devices are usually
installed at each feeder in HV.Black start is a remarkable process and the
controls and instrumentation used during a black start must operate with
the utmost precision and speed.A black start unit is one that can start its

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own power without support from the grid in the event of a major system
collapse. The Black start has the ability of restarting the auxiliary devices of
the generator to recover from a blackout.In the NNPC Towers the blackstart
of the WARTSILA is a 650 KVA Perkins generator.

Figure 24: The WARTSILA Power Plant

ADD… (DIAGRAM & NOTES)

PERKINS GENERATOR
There are four Perkins generators in the towers with a generating power of
1500KV each.It is a V block engine with 12 cylinders. They are primarily
used at night times in the NNPC Towers. Below are the major components
within the perkins generator:
★ Oil filter

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Oil is critical to your generator set as not only does it circulate lubrication
through the moving parts of the engine, but it also enhances fuel efficiency
and prevents deposits and sludge.The role of the oil filter is to remove
impurities such as carbon residue and metal particles from engine oil. If you
continue to use an oil filter after the recommended replacement time, the
engine oil will become more viscous and the filter will become clogged.
This will eventually cause engine problems.
★ The turbocharger
A turbocharger (turbo) is a turbine-driven, forced induction device that
increases an internal combustion engine's power output by forcing extra
compressed air into the combustion chamber.
Turbocharging at elevation is an efficient way to minimize horsepower loss
due to elevation and lower air density. At high elevations, turbochargers
compress more air into the engine cylinders making up for the lower air
density allowing the engine to produce power as if it was at sea level. This
extra tunability is found only in turbocharged applications.
The generator engines will adjust boost pressure and other parameters to
maintain the same power as long as the turbocharger can support the
additional air volume and engine speed.
★ Fuel filter
A fuel filter is located in the fuel line to screen out contaminants such as
dirt, dust, debris and rust particles from the fuel. A fuel filter protects the
critical parts of the engine, by filtering out foreign particles that can
potentially damage a fuel injector.
★ Oil passage
It lubricates all the moving parts when running, reducing wear and prevents
the diesel engine from seizing. It also helps to cool down some parts and it
may help to inhibit corrosion when unused for short periods.
★ Oil sump
The purpose of an oil sump is not simply to store oil, an oil sump has two
other main functions: An oil sump allows oil to settle and this reduces the
likelihood of the oil foaming. The oil sump is designed in such a way as to
allow the oil to be cooled efficiently when the engine is in operation.
★ Rocket arms

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The rocker arm is the part responsible for transmitting the movement of the
camshaft towards the intake and exhaust valves of the engine, a process
that occurs through the direct contact of these parts with the tappets and
according to the movement of the shaft.
★ Kickstarter
Kick-starting prompts the crankshaft to rotate, which in turn pushes the
piston against the piston head, generating friction. It builds up pressure and
a mixture of fuel and air pumped in from the valves gets ignited.
★ Coil
Electric coils are found in electric motors, generators, inductors, and
electromagnets. They serve as a conductor of electricity to efficiently send
electrical current to electric motors. They are a consistent and reliable
method for induction.
A field coil is an electromagnet used to generate a magnetic field in an
electro-magnetic machine, typically a rotating electrical machine such as a
motor or generator. It consists of a coil of wire through which a current
flows.
★ Alternators
A generator alternator is the heart of the generator. The alternator also
referred to as ‘dynamo’ is that part of a generator that produces electrical
energy from the mechanical energy supplied to it by the engine. An
alternator comprises a stator -- a stationary component -- and a rotor -- a
moving component. When both the components work together a relative
movement between the magnetic and electric fields is generated which in
turn produces electricity.
The alternator supplies all of them with direct current (DC) power. Your
alternator is also responsible for charging your car battery while driving.
The alternator works by turning mechanical energy into electrical energy.
When your engine is on, it powers a drive belt that rests on a pulley
attached to the alternator.
★ Water separator
The fuel pre-filter, for example, has the function of separating the water
from the fuel and removing residues that are present in it, preventing them
from being pumped into the engine and causing oxidation issues, corrosion
and cavitation in the cylinders.

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 ★ Radiator
A radiator is fitted to a generator that uses a water cooled diesel engine.
The radiator is used to cool the diesel engine as it runs, to make sure it
doesn't generate an over temperature alarm. If it is air cooled or an
alternative method of cooling is used, such as a heat exchanger, you won't
see a radiator. An example is the Wartsila generator.
How does a diesel generator's radiator work?As a diesel engine runs,
heat is generated during the combustion process. A water cooled engine
has coolant pumped around it as the engine runs and the heat generated is
transferred to the coolant. The coolant is pumped through the radiator,
which has a fan that blows cool ambient air across the radiator matrix /
core. This cool air has the heat from the coolant transferred to it and it is
blown away from the engine. It is important that the hot air is blown away
and is not allowed to recirculate back, because this hot air will not cool the
generator sufficiently.
★ Crankshaft
The crankshaft of an engine is the part that turns the reciprocating motion
generated by the engines pistons to a rotary motion, the rotary motion is
usually output via the engines flywheel. This power in the case of a diesel
generator is used to turn an AC alternator.
★ Camshaft
The camshaft is a mechanical component of an internal combustion
engine. It opens and closes the inlet and exhaust valves of the engine at
the right time, with the exact stroke and in a precisely defined sequence.
The camshaft is driven by the crankshaft by way of gear wheels, a toothed
belt or a timing chain.

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Figure 25: The Perkins Generator

2.1.6 Supply, Installation, Testing And Commissioning Of The Cradles.

The type of cradle to be installed is the cleaning cradle system.A large
number of commercial high-rise buildings in the Central Business
District,Abuja now have external glass curtain walls. Such buildings require
constant maintenance. This is highly dangerous work which should be
carried out by professional cleaners using the cleaning cradle System.
Cradles are widely used for maintenance, cleaning, inspection and
installation work on both the external and internal sides of buildings and
structures. With little noise or vibration, cradles are ideal for working at
height on occupied buildings.A cleaning cradle is a building maintenance
unit(BMU)/ façade access solution that is a common form of access
equipment for external window cleaning and external façade maintenance
for tall buildings.

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The Cradle System provides a fast, safe, versatile, cost effective and a
secure access alternative to traditional scaffolding, being simple to
assemble with minimal tools. Advantages of the cradle system platforms
include;

● Competitive cost compared to scaffolding and mast climbers

● Initial set up and removal is very fast when compared to traditional
methods
● Versatile, modular system allows us to overcome many different
access problems with special platform configurations.
● Suspended access platforms to do not require tie fixings to be drilled
into the structure, suiting glass and cladded facades
● Minimal disruption to the building surroundings
● Reduced security risk to the building (i.e-people climbing scaffolding
to break in)
● Aluminum construction guarantees a lightweight system with a high
load capacity
● In house design and engineering teams offer bespoke systems and
drawings/calculations to support access solutions

Why cradles for the NNPC Towers?

1. The NNPC Towers building needs scheduled maintenance to keep

them in pristine condition.
2. Provide maximum safety to both operator and maintenance
personnel.
3. Safest way to gain access to the sides or high angles surfaces of the
4 towers.
4. Easier for cleaning worker.
5. Improves productivity.
6. Permanent solutions for façade building maintenance.

The NNPC cradle system is a traverse motorized system were a roof car is
designed to move around the roof of the building over a customized rail
track. This is made possible by its motorized undercarriage.

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Figure 23:Cleaning Cradle

Brief Description of some components of the cradle system

1. Electrical system
The electrical system consists of the following main items:
a. On the building
● the main switch, located on the roof
● power supply points, 3-phase + ground, positioned along the track
and protected by a 30 amp circuit breaker (supplied by the customer).
b. On the traversing frame
● the power supply cable for connecting the Roof car frame to the
power points. This cable is stored on a reel under the unit.
● an electrical panel with a control box for the unit.
c. On the platform
● main control panel connected to the roof car by a flexible cable.
Figure 24:Cleaning Cradle’s Control Panel

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2. Lifting mechanism
The lifting mechanism is the electric traction hoist, especially designed for
man-riding applications. The operation of the traction hoist is based on the
principle of pressure pulleys. The gripping of the wire rope in the pulley is
achieved by a set of rollers, activated by a compression spring. LUFFING
BOOM: In this application, the Boom is raised and lowered (Luffed) due to
the action of the Hydraulic Ram.
Figure 25: The Gib Arm
3. Platform
Roof cars suspend a ‘F-type platforms’ as defined by US Federal OSHA
(dual-line suspension). The platforms are driven by hoists on the roof unit,
instead of on the platform. These work platforms are made of aluminum,
clad in perforated aluminum panels. Typical length is 10ft. (3 m), however
this may be increased to a maximum of 36 ft. if required. Typical minimum
capacity is 500 lbs. (220 kg).
Figure 26: The Cradle Basket
4. Traversing frame
The lower frame is constructed of galvanized rectangular steel tube. Four
guide rollers assemblies are fitted to the frame. The 2 front rollers are
powered and the two rear rollers are mounted on an articulated beam to
ensure an even load distribution.
Traversing System: is powered by an electrical motor with a speed
approximately 20 ft./min. (6 m/min.) In general, only the two wheels nearest
the building facade are powered. The Traversing Frame is guided along the
track by guide wheels placed laterally on the wheel assemblies, whether 'L‘
shaped guide track or I-beam track.
Figure 26: The Traversing System and Guide Rollers
Safety Precautions while using cradles.
● They must have guarding that is strong, sturdy and fit-for-purpose.
● The equipment must be inspected regularly and only used by
competent and trained workers.
● Workers need to wear safety harnesses as secondary fall protection.
● Minimum clearance distances should be adhered to when the
equipment is used near overhead electrical cables

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2.2 Knowledge Gained

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