Professional Documents
Culture Documents
SCHEME
( S.I.W.E.S )
REPORT AT
PORT HARCOURT
BY
SUBMITTED TO
BAYELSA STATE
JANUARY 2022
DEDICATION
I also feel indebted to the following people who played various roles to impart their knowledge to
me during my training.
To my colleagues, Adubazi Raphael, Joshua Daniel, and Clever for their support, and creativity and
availability in the dirty job.
Mr. Sunday Adejugbe (Service Manager-Field), under his supervision and tutelage I was able to
grasp the basic rudiment of Power systems and its application.
My mum, who made me never to give up and let go even when the job was tedious.
CHAPTER ONE
INTRODUCTION
Despite dramatic changes and advances in Diesel Engines in the last century,
the most important factor in the operational process is still effective MAINTENANCE.
J+G GLOBAL GAS AND OILFIELD Nigeria Limited (or “the company”) is the
GLOBAL GAS AND OILFIELD LTD Nigeria Limited has operated in Nigeria since 1950
J+G GLOBAL GAS AND OILFIELD LTD Nigeria Ltd provides machines for wide varied
Nigeria. Also, the company provides CAT engines and generators for the oil sector and
industrial users as well as a complete range of lift trucks for material handling
requirements. All machines supplied are kept in working conditions through the
We at J+G GLOBAL GAS AND OILFIELD Nigeria Ltd undertake highly specialized
repairs and machine overhauls with continuous and significant investment in up-to-
date workshop equipment and service tooling. Furthermore, we undertake used
equipment and machine rebuild activities. We have the facilities technology and
adequate tooling to take used machines and rebuild them to an “ as new” standard,
Health, Safety, and Environment: The subsidiaries in Nigeria adhere strictly to the
matters.
ORGANIZATIONAL CHART
In J+G GLOBAL GAS AND OILFIELD Nigeria Ltd, they are two departments which are:
Service Department
Sales Department
Service Department: This is also called the product support, and is divided into
customer’s site.
heavy duty machines like tractors, bulldozers, excavators, pay loaders, etc. both at
Component Rebuild Centre (C.R.C): This is a section in the workshop that specializes
Fluid Analysis/ Scheduled Oil Sample (S.O.S): The S.O.S program is the CAT certified
program of scheduled fluid analysis. Fluid samples collected at routine intervals from
all compartments are analyzed to give you the means to look inside your equipment
and detect problems before they cause a loss of production. Within 24 hours the
sample is analyzed and a report is generated which can warn you of a variety of
Sales Department: This section deals with customer’s service, and the sales of power
system, heavy duty machines and replaceable parts. This section is divided into power
Power System Sales: This section ensure the marketing and distribution sales of power
system.
Machine Sales: This section ensure the marketing and distribution sales of heavy duty
machines.
Part sales department: This section work with the warehouse, were replaceable parts
are stored, which their job is to order parts for demanding customers
CHAPTER TWO
In this section, I understudy, experienced, and felt the heart of a generator set,”
Diesel Engine”. The author will highlight about the working, repair, and maintenance
of diesel engines.
Diesel Engines
Both engines are internal combustion engines, meaning they burn the fuel-air
mixture within the cylinders. Both are reciprocating engines, being driven by
pistons moving laterally in the two directions. The majority of their parts are
similar. Although a diesel engines and gasoline engines operate with similar
greater dynamic forces from the higher combustion pressures present in the
diesel engine.
ratio used by diesel engines. The compression ratio is a measure of how much
the engine compresses the gasses in the engine's cylinder. In a gasoline engine
by the air-fuel mixture entering the cylinders. The lower ignition temperature of
gasoline will cause it to ignite (burn) at a compression ratio of less than 10:1.
The average car has a 7:1 compression ratio. In a diesel engine, compression
ratios ranging from 14:1 to as high as 24:1 are commonly used. The higher
compression ratios are possible because only air is compressed, and then the
fuel is injected. This is one of the factors that allow the diesel engine to be so
module. Another difference between a gasoline engine and a diesel engine is the
manner in which engine speed is controlled. In any engine, speed (or power) is
engines are self-speed-limiting, due to the method the engine uses to control
the amount of air entering the engine. Engine speed is indirectly controlled by
the butterfly valve in the carburetor. The butterfly valve in a carburetor limits
the amount of air entering the engine. In a carburetor, the rate of air flow
dictates the amount of gasoline that will be mixed with the air. Limiting the
amount of air entering the engine limits the amount of fuel entering the engine,
and, therefore, limits the speed of the engine. By limiting the amount of air
entering the engine, adding more fuel does not increase engine speed beyond
the point where the fuel burns 100% of the available air (oxygen).
entering the engine is always the maximum amount. Therefore, the engine
speed is limited solely by the amount of fuel injected into the engine cylinders.
Therefore, the engine always has sufficient oxygen to burn and the engine will
attempt to accelerate to meet the new fuel injection rate. Because of this, a
condition, can accelerate at a rate of more than 2000 revolutions per second.
Diesel engines require a speed limiter, commonly called the governor, to control
the amount of fuel being injected into the engine. Unlike a gasoline engine, a
diesel engine does not require an ignition system because in a diesel engine the
fuel is injected into the cylinder as the piston comes to the top of its
compression stroke. When fuel is injected, it vaporizes and ignites due to the
good time. In a diesel engine, all the components work together to convert heat
Combustion: this is the heating of air and fuel together to produce combustion,
which creates the force required to run the engine. It occurs when the air-fuel
Working Principle
There are different type’s cycles in thermodynamics. Such as Otto cycle, Carnot
vapor cycle, Diesel cycle etc. Out of that cycle diesel engine works on diesel
cycle. This cycle is also known as constant pressure cycle. Diesel engine is
In Petrol Engine, the air-fuel mixture after being compressed in the engine
diesel engine, diesel oil and light and heavy oil used as fuel. This fuel is ignited
by being injected into the engine cylinder containing air compressed to a very
high pressure; the temperature of this air is sufficiently high to ignite the fuel.
That is why there is no spark plug used in diesel engine. This high temperature
compressed air used in the form of very fine spray is injected at a controlled
01) Suction Stroke:- In this stroke, the piston moves down from the top dead
centre. As a result, inlet valve opens and air is drawn into the cylinder. After
sufficient quantity of air with pressure is drawn, suction valve closes at the end
of the stroke. The exhaust valve remains closed during this stroke.
02) Compression Stroke:- In this stroke, piston moves up from the bottom dead
centre. During this stroke both inlet and exhaust valve are closed. The air
drawn into the cylinder during suction stroke is entrapped inside the cylinder
and compressed due to upward movement of the piston. In diesel engine, the
compression ratio used is very high as a result, the air is finally compressed to
a very high pressure up-to 40 kilogram per centimeter square, at this pressure,
and the temperature of the air is reached to 1000 degree centigrade which is
03) Constant Pressure Stroke:- In this stroke, the fuel is injected into the hot
When the piston moves to its top dead centre, the supply of fuel is cut-off. It is
to be said that the fuel is injected at the end of compression stroke and
injection continues till the point of cut-off, but in actual practice, the ignition
starts before the end of compression stroke to take care of ignition tag.
04) Working or Power Stroke:- In this stroke, both inlet and exhaust valve
remain closed. The hot gases (which are produced due to ignition of fuel during
cylinder pushing the piston down and hence work is done. At the end of stroke,
05) Exhaust Stroke:- In this stroke, the piston again moves upward. The
exhaust valve opens, while inlet and fuel valve are closed. A greater part of the
burnt fuel gases escape due to their own expansion. The upward movement of
the piston pushes the remaining gases out through the open exhaust valve.
Only a small quantity of exhaust gases stay in the combustion chamber. At the
end of exhaust stroke, the exhaust valve closes and the cycle is thus
completed.
As there is some resistance while operating in inlet and exhaust valve and the
some portion of burnt gases remains inside the cylinder during the cycle,
resulting the pumping losses. This pumping loss are treated as negative work
and therefore subtracted from actual work done during the cycle. This will give
One big difference between a diesel engine and a gas engine is in the injection
injection system injects fuel just prior to the intake stroke (outside the
cylinder). A carburetor mixes air and fuel long before the air enters the
cylinder. In an engine, therefore, all of the fuel is loaded into the cylinder
during the intake stroke and then compressed. The compression of the fuel/air
mixture limits the compression ratio of the engine -- if it compresses the air too
Diesel engines use direct fuel injection -- the diesel fuel is injected directly into
the cylinder.
The injector on a diesel engine is its most complex component and has been
temperature and pressure inside the cylinder and still deliver the fuel in a fine
mist. Getting the mist circulated in the cylinder so that it is evenly distributed
is also a problem, so some diesel engines employ special induction valves, pre-
Some diesel engines contain a glow plug. When a diesel engine is cold, the
compression process may not raise the air to a high enough temperature to
ignite the fuel. The glow plug is an electrically heated wire (think of the hot
wires you see in a toaster) that heats the combustion chambers and raises the
air temperature when the engine is cold so that the engine can start. According
coolant and oil temperatures and even engine position (i.e. T.D.C.). Glow plugs
are rarely used today on larger engines. The ECM senses ambient air
temperature and retards the timing of the engine in cold weather so the
injector sprays the fuel at a later time. The air in the cylinder is compressed
Smaller engines and engines that do not have such advanced computer control
Of course, mechanics aren't the only difference between diesel engines and
Common Rail
The Common Rail system also has a lift/transfer pump and a high pressure pump.
The high pressure pump pressurizes the fuel which is then sent to a rail connected to
all injectors. Unlike the other systems, the injectors are solenoids controlled by the
ECU (Electronic Control Unit). The ECU uses information from the vehicle sensors to
and how they work together is necessary. Figure 5 provides a cross section of
Components of diesel engines are divided into stationary parts and moving
parts.
Stationary Parts: these are parts of an engine which include cylinder block,
cylinder liner, bore, cylinder block, crankcase and the exhaust and inlet
manifolds.
unit made from cast iron. In a liquid-cooled diesel, the block also provides the
structure and rigid frame for the engine's cylinders, water coolant and oil
Crankcase and Oil Pan: The crankcase is usually located on the bottom of the
cylinder block. The crankcase is defined as the area around the crankshaft and
crankshaft bearings. This area encloses the rotating crankshaft and crankshaft
counter weights and directs returning oil into the oil pan. The oil pan is located
at the bottom of the crankcase as shown in Figure 5. The oil pan collects and
stores the engine's supply of lubricating oil. Large diesel engines may have the
Cylinder Head and Valves: This provides the combustion chamber for the
engine cylinders. The cylinder bolted to the top of the cylinder block to close
the upper end of the cylinder. A diesel engine’s cylinder heads perform several
functions. First, they provide the top seal for the cylinder bore or sleeve.
Second, they provide the structure holding exhaust valves (and intake valves
where applicable), the fuel injector, and necessary linkages. A diesel engine's
heads are manufactured in one of two ways. In one method, each cylinder has
its own head casting, which is bolted to the block. This method is used
primarily on the larger diesel engines. In the second method, which is used on
smaller engines, the engine's head is cast as one piece (multi-cylinder head).
Diesel engines have two methods of admitting and exhausting gasses from the
cylinder. They can use either ports or valves or a combination of both. Ports are
slots in cylinder walls located in the lower 1/3 of the bore. See Figure 5 for
examples of intake ports, and note their relative location with respect to the
rest of the. When the piston travels below the level of the ports, the ports are
"opened" and fresh air or exhaust gasses are able to enter or leave, depending
on the type of port. The ports are then "closed" when the piston travels back
above the level of the ports. Valves (refer to figure 8) are mechanically opened
and closed to admit or exhaust the gasses as needed. The valves are located in
the head casting of the engine. The point at which the valve seals against the
head is called the valve seat. Most medium-sized diesels have either intake
(b)
Figure 7: (a) Caterpillar 3600 series cylinder head and (b) Engine Valve.
Exhaust Manifolds: An exhaust manifold is a system which is used to vent exhaust
gases away from an engine. The manifold extends from the cylinders to the exhaust
pipe, collecting and moving exhaust away from the engine. Exhaust can be harmful to
inhale, making it very important to have a fully functional exhaust manifold; because
it can sometimes be difficult to detect an exhaust leak, people may inhale exhaust
gases without being aware of it. When the pistons in the engine reach the exhaust
stroke, they push the exhaust fumes up into the exhaust manifold. The manifold
consists of a series of pipes which connect to the cylinders and then consolidate in a
central large pipe which vents to the exhaust pipe. A series of gaskets are used to
create tight seals so that exhaust cannot escape from the cylinders. One of the most
common problems which can arise with an exhaust manifold is damage to the gasket
which acts as a seal. In this case, the manifold needs to be unbolted so that the gasket
can be removed and replaced. Another issue which can commonly arise is rust,
especially in salty environments. If rust eats through the pipes of the manifold, they
can start to leak exhaust fumes into the engine compartment. In generators, these
into mechanical energy. They further convert motion into rotary motion. The principal
moving parts are the piston assembly, connecting rods, crankshaft assembly (includes
Piston Assembly: The piston transforms the energy of the expanding gasses into
mechanical energy. The piston rides in the cylinder liner or sleeve as Shown in Figure
5. Pistons are commonly made of aluminum or cast iron alloys. To prevent the
combustion gasses from bypassing the piston and to keep friction to a minimum, each
These rings function as the seal between the piston and the cylinder wall and
also act to reduce friction by minimizing the contact area between the piston
and the cylinder wall. The rings are usually made of cast iron and coated with
chrome or molybdenum. Most diesel engine pistons have several rings, usually
2 to 5, with each ring performing a distinct function. The top ring(s) acts
primarily as the pressure seal. The intermediate ring(s) acts as a wiper ring to
remove and control the amount of oil film on the cylinder walls. The bottom
ring(s) is an oiler ring and ensures that a supply of lubricating oil is evenly
Connecting Rod: The connecting rod connects the piston to the crankshaft. See
Figure 5 for the location of the connecting rods in an engine. The rods are
Each end of the rod is bored, with the smaller top bore connecting to the piston
pin (wrist pin) in the piston as shown in Figure 9. The large bore end of the rod
is split in half and bolted to allow the rod to be attached to the crankshaft.
Some diesel engine connecting rods are drilled down the center to allow oil to
travel up from the crankshaft and into the piston pin and piston for
rods is to position the cylinders in the left and right banks directly opposite
arrangement requires that the connecting rods of two opposing cylinders share
the same main journal bearing on the crankshaft. To allow this configuration,
one of the connecting rods must be split or forked around the other.
bearing and connecting rod bearing surfaces. The rod bearings are eccentric, or
offset, from the center of the crankshaft as illustrated in Figure 11. This offset
converts the reciprocating (up and down) motion of the piston into the rotary
motion of the crankshaft. The amount of offset determines the stroke (distance
the piston travels) of the engine (discussed later). The crankshaft does not ride
directly on the cast iron block crankshaft supports, but rides on special
bearing material as shown in Figure 11. The connecting rods also have
bearings inserted between the crankshaft and the connecting rods. The bearing
material is a soft alloy of metals that provides a replaceable wear surface and
prevents galling between two similar metals (i.e., crankshaft and connecting
rod). Each bearing is split into halves to allow assembly of the engine. The
crankshaft is drilled with oil passages that allow the engine to feed oil to each
of the crankshaft bearings and connection rod bearings and up into the
connecting rod itself. The crankshaft has large weights, called counter weights,
that balance the weight of the connecting rods. These weights ensure an even
Flywheel: The flywheel is located on one end of the crankshaft and serves three
purposes. First, through its inertia, it reduces vibration by smoothing out the
power stroke as each cylinder fires. Second, it is the mounting surface used to
bolt the engine up to its load. Third, on some diesels, the flywheel has gear
teeth around its perimeter that allow the starting motors to engage and crank
the diesel.
valve and fuel injector. Each lobe has a follower as shown on Figure 13. As the
camshaft is rotated, the follower is forced up and down as it follows the profile of the
cam lobe. The followers are connected to the engine's valves and fuel injectors through
various types of linkages called pushrods and rocker arms. The pushrods and rocker
arms transfer the reciprocating motion generated by the cam shaft lobes to the valves
and injectors, opening and closing them as needed. The valves are maintained closed
by springs.
As the valve is opened by the camshaft, it compresses the valve spring. The energy
stored in the valve spring is then used to close the valve as the camshaft lobe rotates
out from under the follower. Because an engine experiences fairly large changes in
components must be designed to allow for thermal expansion. Therefore, the valves,
valve pushrods, and rocker arms must have some method of allowing for the
expansion. This is accomplished by the use of valve lash. Valve lash is the term given
to the "slop" or "give" in the valve train before the cam actually starts to open the valve.
The camshaft is driven by the engine's crank shaft through a series of gears called
idler gears and timing gears. The gears allow the rotation of the camshaft to
correspond or be in time with, the rotation of the crank shaft and thereby allow the
valve opening, valve closing, and injection of fuel to be timed to occur at precise
intervals in the piston's travel. To increase the flexibility in timing the valve opening,
valve closing, and injection of fuel, and to increase power or to reduce cost, an engine
may have one or more camshafts. Typically, in a medium to large V-type engine, each
bank will have one or more camshafts per head. In the larger engines, the intake
valves exhaust valves, and fuel injectors may share a common camshaft or have
independent camshafts.
Depending on the type and make of the engine, the location of the camshaft or shafts
varies. The cam shaft (s) in an in-line engine is usually found either in the head of the
engine or in the top of the block running down one side of the cylinder bank. Figure 14
provides an example of an engine with the camshaft located on the side of the engine.
On small or mid-sized V-type engines, the camshaft is usually located in the block at
the center of the "V" between the two banks of cylinders. In larger or multi-cam
shafted V type engines, the camshafts are usually located in the heads.
to form a cylinder. It is one of the most important functional parts to make up the
interior of an engine.
This is called Cylinder liner in Japan, but some countries (or companies) call this
Cylinder sleeve.
CONDITION MONITORING
maintenance tool used to avoid potential problems which may occur at later
Methods of Maintenance
PROBLEMS ENCOUNTERED
I did not encounter any major problem but I must not fail to mention at this
point that months into the training program most of my colleagues were to
This industrial training has really exposed me to lots things and challenges.
One major thing achieved is the ability to fully participate in full overhauling of
CHAPTER 4
with the various companies in the country in order to increase the number of
They should try as much as they can to build relationship and make contact in
their company.
SIWES on its own part should make available a general format for all
SIWES should try to visit the trainees before the end of their program in which
Conclusion
The training has been valuable benefit to me. It has presented a great
inexperience status. The period too has given me the opportunity to familiarize
myself with the cultures and workings of no less a company than J+G GLOBAL
sincerely thank them for the brilliant decision to get me thoroughly trained in