CHAPTER 1

1.0 INTRODUCTION

The students Industrial Work Experience Scheme (SIWES) is the accepted skills training

program, which forms part of the approved minimum standard in the various degree programs

for all the Nigerian universities. The scheme bridges the gap existing between theory and of the

Engineering and Technology, Sciences, Agriculture, Medical, Environmental Sciences,

Technical and Science Education and other professional educational programs in the Nigerian

tertiary institutions. It is aimed at exposing students to machines and equipment, professional

work methods and ways of safeguarding the work areas and workers in the industries and other

organizations.

The minimum duration for SIWES is twenty four (24) weeks. SIWES is a tripartite program

involving the students, the universities and the industries. The program was established by the

Federal Government of Nigeria and is jointly co-ordinated by the Industrial Training Fund (ITF)

and the National Universities Commission (NUC).

The responsibilities of Students in SIWES training program is mainly of three stages: Pre-

SIWES stage, SIWES stage and Post-SIWES stage.

1.1 OBJECTIVES OF SIWES

Specifically, the objectives of the students Industrial Work Experience Scheme (SIWES)

according to the industrial training fund are to:

1
 a. provide an avenue for students in institutions of higher learning to acquire industrial

skills and experience in their courses of study;

b. Prepare students for the industrial work situations they are to meet after graduation;

c. expose students to work methods and techniques in handling equipment and machinery

that may not be available in their institutions;

d. make the transition from school to the world of work easier, and enhance students

contacts for later job placement;

e. Provide students with an opportunity to apply their knowledge in real work situation

thereby bridging the gap between theory and practice.

f. Enlist and strengthen employers’ involvement in the entire educational process and

prepare students for employment after graduation.

1.2 BEGINNING OF INDUSTRIAL TRAINING

In a quest to have industrial training I got myself attached to CADPLUS INNOVATIONS, an

Engineering CAD software Training company for some time to get myself trained on some

engineering software then proceeded to the Estate, Works and Transport department of

Rivers State University of Science and Technology, Port Harcourt.

2
1.2.1 About CADplus Innovations

CADplus Innovations Company is a company that train students of engineering, Oil and Gas

workers, and other interested persons on Engineering CAD software such as:

 Autodesk autoCAD

 Autodesk inventor

 Autodesk civil 3D design

 Autodesk autoCAD mechanical

 Autodesk autoCAD electrical

 PDMS etc.

It is located on the second floor of the Engineering Faculty of RSUST.

1.3 ABOUT ESTATE, WORKS AND TRANSPORT DEPARTMENT OF RSUST.

The Estate, Works and Transport Department provides engineering and maintenance services to

existing University owned or rented physical structures. The engineering services involve the

planning, design, development and construction of institutional facilities to meet the ever-

growing demands of the University. Maintenance services involve the sustenance, repairs and

upkeep of existing facilities.

3
The services of the department are rendered through four main divisions namely:

Electrical/Mechanical; Civil/Building; Estate Administration; and the Estate Unit at RIART,

Onne. The Electrical/Mechanical division carries out all the electrical services, and the

mechanical operations and maintenance of the generating stations, water pumping stations,

central air-conditioning systems, tractors, slashers and distribution installation works with

regards to electricity. It also liaises with the National Electric Power Authority (NEPA) now Port

Harcourt Electricity Distribution Company (PHEDC) to ensure an uninterrupted supply of

electricity to the University.

The Civil/Building division undertakes the maintenance of campus roads, drainage systems,

grounds and sewage disposal systems, carpentry and joinery works, masonry, sign-writing and

painting works, the repairs and construction of furniture and the construction of buildings by

direct labour. The functions of the department are carried out through the following divisions and

units:

(a) PROJECTS AND ENVIRONMENT DIVISION

(i) Projects Unit

This unit is responsible for the planning, design, development and construction of

new projects.

(ii) Environment Unit

This unit is responsible for the upkeep of lawns, grounds, disposal of solid waste, sewage and

drainage systems.

4
(b) BUILDING/CIVIL DIVISION

This division is responsible for the general maintenance of Building and Civil works like

drainage, roads, culverts, etc. General maintenance including carpentry and joinery works,

masonry, plumbing, electrical installations, painting, sign-writing, decoration, the repairs and

construction of furniture and the construction of building by direct labour.

(c) ELECTRICAL/MECHANICAL DIVISION

This division is responsible for the maintenance of electrical installations and other electrical

repairs and the distribution of water. Also repairs of mechanical equipment like boreholes,

vehicles, welding and other mechanical repairs.

(d) THE TRANSPORT UNIT

This unit is responsible for management and repairs of vehicles, management of drivers. This

unit is directly responsible for the director of works.

(e) THE TELECOMMUNICATIONS UNIT

The telecommunication unit is responsible for the maintenance and repairs of all

telecommunication equipment.

(f) THE ESTATE ADMINISTRATION AND STORES

This division is responsible for the general administration of Estate Services like receiving and

dispatching of mails, general secretarial and clerical jobs. Also takes stock, issue of materials in

the Estate Store. The unit is directly under the Director of Works.

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(g) ELECTRICITY GENERATION AND DISTRIBUTION COMMITTEE

The University Administration set up an Electricity Generation and Distribution Committee in

1997 to take charge of the distribution and generation of Electricity on Campus. The Committee

is made up of staff of this Department but are attached to the Vice-Chancellor’s office.

(h) ESTATE MAINTENANCE UNIT AT THE RIVERS INSTITUTE OF

AGRICULTURAL RESEARCH AND TRAINING (RIART). ONNE

This unit takes care of the general maintenance of engineering services at the Onne Campus. The

current Acting Director of Works Engineer Justice N. E. Chukwu.

6
ESTATE AND WORK DEPARTMENT ORGANOGRAM

DIRECTOR OF WORKS

HEAD MECH. & HEAD PROJECT & HEAD ADMIN HEAD BUILDING & CIVIL
DIVISION ELECT.
DEVELOPMENT

SECTION

HEAD HEAD HEAD HEAD HEAD HEAD HEAD HEAD HEAD

SANITATION ACCOUNT STORE BUILDING
MECH. ELECTRICAL ESTATE TRANSPORT
CIVIL

UNIT

HEAD HEAD VEHICLE HEAD HEAD HEAD R/A HEAD HEAD HEAD HEAD HEAD
WELDING MAINTENANCE PLUMBING ELECT. GLAZER PAINTING CARPENTRY MASON LABOUR
W/SHOP

Fig.1.0 Estate and Works Organogram

7
1.3.1 THE OLD SITE POWER HOUSE

There are two power houses in the university campus which are responsible for power generation

and distribution the whole University Campus. They are the Old Site Power House and the Estate

Power House. The Old Site Power House being the official place of attachment during my

Industrial Training (I.T) period supplies electric power to a portion of the University community;

such as Shopping complex, Hospital, Lecturers’ Residential buildings, Vice Chancellor’s office

complex, Main offices/Hostels, Marine Engineering Laboratory, Amphitheatre and the Old site

Panel Room.

It has three Power Generating Plants of different power ratings; the 2000KVA and 1275KVA

CAT generator plants and an 800KVA Perkins generator. The 2000KVA is a V-shaped engine

and has Sixteen Cylinders hence it is a V-16 Engine. Likewise the 1275KVA with V-shape and

twelve (12) Cylinders is otherwise called a V-12 Engine.

Fig.1.1 Pictures showing the 1275KVA and 2000KVA Power Plants

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Also in the Old Site Power House is an ABB MAIN LOW VOLTAGE SWITCHGEAR (MAIN

LV SWGR). This is an Analogue operated power control panel. It has two units known as Bus-

Bars. On each bus-bar are five sections making a total of Ten (10) sections on the Panel, the both

Bus-bars are linked together by a section on the panel known as the BUS COUPLER. This

allows the flow of electric power from any of the Bus-bars uniformly through the different

circuits on the sections for power distribution. Below is a picture showing the cross section of the

Low Voltage Switch Gear panel.

Fig. 1.2 picture showing the cross section of ABB LV SWGR at Old Site Power House
9
 CHAPTER TWO (2)

INDUSTRIAL EXPERIENCE

2.0 GENERAL SAFETY

Every organization has the responsibility of protecting their equipment and the lives of those

working in their premises from damages and possible dangers that may cause loss of lives

and possible injury. Thus the condition of being protected from or unlikely to cause danger,

risk, or injury is termed SAFETY.

Office Safety

It is an unsafe act to leave switches on at the close of work each day. It is advisable to switch

all switches off to avert the risk of fire accident. Unplug all computer sets used for each day

at the close of work to avoid being damaged and also shut down all computer systems to

avoid battery draining.

Possible Dangers and Safety measures in Power House

During power generation from the power plants there is the tendency of great noise

production which can cause permanent deafness to the operators if not well protected

personally. The production of heat by the Power Plants can cause skin irritation to the poorly

or unprotected operators. Also the oil that may split on the floor of the building can cause

domestic accident by slipping off any person that may mistakenly step on it.

In the panel room where we have the incomer and distribution breakers installed should be

equipped with suitable fire extinguisher for Class C fire since Class C fire results from

electrical equipment like breakers, wiring and outlets.

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These and many more Dangers could be prevented by being fully kitted with Personal

Protective Equipment (PPE) such as the Ear muffs or ear plugs for protection of the ears,

Cover all helps in protecting the skin from direct heat generated from the power plants,

Safety shoes/boots will help prevent against any accident that may result from stepping on

spilled oil on the ground.

2.1 THE ENGINE SYSTEMS

Before I talk about the steps taken in the servicing of the CAT power plants at Old Site power

house, let us look into the systems of the engine and they work. All engines are made up of

systems which function together to give the required performance of the engine. This can be

likened to the human body that is made up of systems which work in synergy to make us

what we are. So to continue in our healthy state there must be routine check on our bodies for

proper maintenance. This is also applicable to machines or engines to keep them in good

state. Let us consider the different systems of the diesel engine. Diesel engines have the:

Cooling System, Lubrication System, Fuel System, Air Intake and Exhaust System and

Electrical System.

The Cooling System

Fig.2.3. components of cooling system

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Cooling System is the source of over 40% of engine problems. Among the five systems,

Cooling System is the most critical to engine life. The components that make up the cooling

include:

 Water Pump – The water pump provides continuous circulation of coolant whenever

the engine is turning. Water pumps on Cat engines are generally gear driven, except

on the 3208, 3114, and 3116 Engines which have belt driven water pumps.

 Radiator – The radiator transfers heat away from the coolant, lowering the coolant

temperature. The coolant flows through the radiator tubes while air circulates around

the tubes providing a transfer of heat to the atmosphere. There are three types of

radiators, conventional-style, folded core, and the modular core radiator.

 Coolant – Coolant is a mixture of water, antifreeze (glycol), and coolant conditioner

(inhibitor). For proper cooling each must be maintained in the correct proportion.

 Thermostat – The thermostat is technically called a temperature regulator. It assists

in the engine warm-up and helps maintain coolant and engine temperature during

operation. When the engine is cold the thermostat allows coolant circulation just

through the engine, bypassing the radiator (to help the engine warm-up).

When the engine is at proper operating temperature the thermostat opens to allow

coolant flow through the radiator (so cooling takes place). The thermostat opens and

closes with respect to change in coolant temperature.

 Water Temperature Gauge – The water temperature gauge indicates the

temperature of the coolant. The recommended operating range is generally between

190o – 210oF (88o – 99oC).

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  Fan – The fan forces air around the radiator tubes to transfer heat out of the coolant

and decrease coolant temperature. Fans are belt driven off a crankshaft pulley.

 Oil Coolers – Oil coolers function to maintain the correct temperature of engine,

transmission and hydraulic oil. There are two types: oil to coolant ant oil to air.

How Cooling System Works

Fig. 2.4.how cooling system works

The primary function of the cooling system is to maintain engine temperature correctly by

taking away unwanted heat generated by combustion and friction. Approximately 33% of the

developed heat energy during combustion is converted into usable horsepower, 7% radiates

directly off engine surfaces and 30% out the exhaust. The remaining 30% dissipated by the

cooling system.

Coolant circulates through passages in the engine called water or coolant jackets. The coolant

absorbs heat from the hot engine surfaces and carries it to the radiator where it transfers to the

atmosphere.

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How Coolant Flows Through the Engine

1. Coolant flow is initiated by the water pump that starts and continues pumping as soon

as the engine is started.

2. Coolant circulates through the engine oil cooler to cool the engine oil.

3. From the oil cooler, coolant travels into the engine block and around the hot cylinder

liners picking up heat and cooling engine parts.

4. Then it travels through intricate passages in the cylinder head(s) picking up more heat

around the critical valve areas.

From the cylinder head(s) the coolant goes to the thermostat and on to the radiator for

cooling. If the engine is cold, the thermostat will remain closed and will re-circulate the

coolant through the engine bypassing the radiator. See picture below how coolant flows in the

engine as described above.

Fig.2.5 Coolant flow through the engine

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Engines with turbochargers and after-coolers circulate partial flow of coolant from the water

pump directly to the after-cooler. Here the coolant is used to lower the air temperature so that

more air can be packed in the cylinder. This allows more fuel to be burned and creation of

higher engine horsepower output.

Cooling System Problems

The cooling system causes most engine failures than the Lubrication system. A cooling

system that runs so cold causes marginal lubrication because the low temperature prevents

the oil from warming up so that it can flow and coat parts adequately. A cooling system that

runs too hot also causes marginal lubrication because the high temperatures break down the

properties of the oil so that parts are not protected correctly. Both cases of marginal

lubrication can be traced back to cooling system problems. Thus the major problems

associated with cooling system are Overheating and Overcooling.

Lubrication System

The engine lubrication system has three main functions: to clean, cool, and lubricate parts.

 Cleaning: Oil clean parts by carrying away damaging metal particles that materialize

during normal engine operation. It also clean the cylinder walls and carries away

carbon and lacquer deposits during combustion.

 Cooling: Cooling parts by absorbing and carrying away heat is the second function

engine oil.

 Lubricating: Thirdly, oil forms a thin film or layer between the surfaces of moving

parts to support and separate them. This prevents metal-to-metal contact that causes

excessive wear.

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The components of the lubrication system include the following.

Fig.2.6. Components of lubrication system

Oil Pump – The oil pump operates whenever the engine is turning to provide

continuous circulation of oil through the engine.

Oil Cooler – Coolant circulates through the oil cooler providing a heat transfer, from the

oil to the coolant. This lowers the oil temperature and protects the oil properties.

Oil Filter – The oil filter cleans the oil by collecting metal particles and other debris that

can damage engine parts.

Oil Level Gauge (dipstick) – The dipstick provides a method to check the amount of oil

in the engine.

Oil Pressure Gauge – The oil pressure gauge indicates the pressure in the engine

lubrication system during engine operation.

Oil Pan – The oil pan (sump) bolts to the bottom of the engine and is the reservoir for

the engine oil.

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 Oil Fill Pipe – This is where the oil is poured into the engine.

How Lubrication System Works

Fig.2.7 how lubrication system works

1. Oil travels from the oil pan (sump) at the bottom of the engine, up through the oil

pump and

2. Then to the oil cooler. Here the oil is cooled by engine coolant.

3. Then the oil goes through the oil filter(s) where debris and contaminants are removed.

4. Clean oil then moves into the oil manifold where it goes in two directions:

a. Into the engine to lubricate components, such as the bearings, gears, pistons,

liners, valves etc.

b. And a smaller flow directly to the turbocharger.

The oil then returned to the oil sump (pan) to start the cycle again. A bypass valve in the filter

base allows unfiltered oil to by-pass a plugged filter so the engine will have some oil. When

the oil is cold an oil cooler bypass valve bypasses oil around the oil cooler during start-up.

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The problems of associated with lubrication which can cause excessive wear are: inadequate

lubrication and contaminants in oil. Inadequate lubrication can result to cold engine starts.

Recommended start-up procedures will eliminate this problem and help prolong engine life.

Other causes of inadequate lubrication include: Wrong Viscosity of Oil, Not Enough Oil, and

Overcooling. Contaminants in Oil – This is the second type of lubrication problem. This is

caused by extended oil change periods. When oil changes are pushed beyond the

recommended period there is a breakdown of the oil itself and loses its ability to suspend

contaminants, something similar to a contaminant overload. When this happens,

contaminants embed themselves in bearing surfaces, and other moving parts causing damage

and wear.

Fuel System

It is the function of the fuel injection pump and injectors to supply fuel into each cylinder in

the amount and at the right time for efficient combustion. The components of the fuel system

include the following.

 Fuel Tank – The tank is the reservoir for holding fuel.

 Fuel Injection Pumps – There is one fuel injection pump for each cylinder. Unlike

the fuel transfer pump which is low pressure, the fuel injection pumps operate at high

pressure. Injection pressure can run from 2,800 to 20,000 psi (19,290 to 137,800 kpa).

Each pump meters the correct amount of fuel and pumps it, at high pressure, through

the metal lines to each fuel injector.

 Unit Injectors – The unit injector combines a fuel injection pump and a fuel injector

into one assembly. Unit injectors eliminate high pressure fuel lines between the pump

and injector allowing for higher fuel injection pressures.

 Fuel filters – Fuel passes first through a primary then a secondary fuel filters. It’s

critical to have clean fuel for these high pressure pumps.

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  Water Separator – Water separators are used to protect against rust caused by water-

contaminated fuel.

 Fuel Pressure Gauge – This gauge reads the pressure generated by the fuel transfer

pump downstream from the filters. If a filter becomes plugged a pressure reduction

will show on the gauge.

 Fuel Lines – Fuel lines are most commonly defined as those from the fuel injection

pump housing to the injectors. On pre-combustion and direct injection engines the

fuel lines carry high pressure fuel. Since unit injectors have the injection pumps both

into the injector assembly, they do not have high pressure lines.

How the Fuel System Works

There are two methods of delivering fuel into the combustion chamber; the first is pre-

combustion, where fuel begins ignition in a pre-combustion chamber before going into the

cylinder; and the second is direct injection, in which the fuel is injected directly into the

cylinder for combustion.

It is also important to understand unit fuel injectors which are used on many of the latest Cat

engines. Unit injectors use direct injection method of fuel delivery but they are different from

engines with traditional pre-combustion and direct injection systems.

Fuel travels through all Cat Engines in basically the same way, up until the point of fuel

injection. (1) Fuel goes from the tank (2) through a water separator, (3) through a primary

fuel filter, and (4) into the fuel transfer pump. (The primary filter can be before or after the

transfer pump). From the transfer pump fuel (5) Goes to a secondary filter, and then either (6)

to a fuel injection pump (pre-combustion and direct injection) or a unit injector.

Many of the latest model Cat engines, including the 3500 and 1.1 Liter Engines use unit fuel

injectors. Fuel System Problems can be diagnosed as Under-fueling which occurs when

there is not enough fuel to meet the power demands on the engine. It doesn’t normally

19
damage the engine but causes lack of power. This can be indicated by low power and low

pressure (plugged filter). Another problem of fuel system is Incorrect Fuel; this is indicated

by difficult starting engine and engine cutting out.

Over-Fueling: This occurs when there is much fuel is injected into the cylinder. Excessive

black smoke is the leading warning sign. There are many causes, such as a high fuel rack

setting, misadjusted air/fuel ratio control or faulty injector.

Air Intake and Exhaust System

The air intake system supplies clean air for engine combustion. The exhaust system takes

away exhaust gases and heat, and drives the turbocharger. The components that make up the

air intake and exhaust system include the following;

 Pre-cleaner – The pre-cleaner removes large particles of dirt and debris.

 Air Filters – Usually there are two air filters, a primary and secondary filter. They

collect contaminants and prevent dirt from entering the engine.

 Air Service Indicator – The indicator monitors restriction through the air filters. It is

the most accurate method for determining when to change air filters.

 Turbocharger – Exhaust gases drive the turbocharger which pumps additional air

into the engine allowing more fuel to be burned, thereby increasing the horsepower

output.

 After-Cooler – The after-cooler cools the air after it leaves the turbocharger before it

enters the engine. This increases the air density, so more air can be packed into each

cylinder.

 Air Intake and Exhaust Manifolds – The air intake and exhaust manifold connect

directly to the cylinder head(s). The intake manifold distributes clean air from the

20
 turbocharger into each cylinder, while the exhaust manifold takes exhaust gases from

each cylinder and directs them to the turbocharger and/or muffler.

 Muffler – The muffler reduces the sound level and provides sufficient back pressure

to the engine, so the engine “breathes” as designed.

How the Air Intake and Exhaust System Works

1. Air first enters the system via the pre-cleaner. Here large dirt particles are removed.

2. Then air moves through the primary and secondary air filters for cleaning. On the

turbocharged engines the spinning of the turbocharger compressor wheel pulls air into

the turbocharger.

3. The compressor wheel compresses the air (which also heats it) and sends it to the

after-cooler. The after-cooler reduces the air temperature making it denser so more air

can be packed into the cylinders.

4. The dense compressed air moves from the after-cooler through the air intake manifold

and cylinder head(s)

5. Past the intake valves into each cylinder combustion chamber. As the intake valves

close and the piston moves up in the cylinder the air is further compressed. When the

piston is near the top of its stroke (TDC), fuel is injected into the combustion

chamber. The fuel mixes with the hot compressed air in the ratio of 16 : 1 and ignites.

The force of combustion pushes the piston down on the power stroke.

6. When the piston moves up again it is on the exhaust stroke. The exhaust valves open

allowing exhaust gases out through the exhaust manifold.

Signs of Air Intake and Exhaust Problems are;

Black smoke,

Low power, and

Hard starting.

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Electrical System

Fig.2.8 components of electrical system

The primary function of a diesel engine’s electrical system is to start the engine. The

secondary function is to power lights, gauges and vehicle electrical components. In diesel

engine it is important to note that after cranking, the battery is no longer needed to continue

running because there is no ignition system required for combustion, as on gasoline.

Major Components of the Electrical System

 Battery – The battery stores electrical energy

 Alternator – The alternator creates electrical energy to replenish the charge level in

the battery. A voltage regulator is inside the alternator.

 Starter – The starter motor is powered by electricity from the battery. Its function is

to start the engine.

 Glow plugs – Glow plugs preheat the air for easier engine starting. They are only

found on pre-combustion engines.

How the Electrical System Works

The battery stores energy and provides the power needed for the electrical starter to crank the

engine. As electrical energy is used out of the battery it has to be replenished. The alternator

develops energy during machine operation to replenish the battery.

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2.2.0 ACTIVITIES PERFORMED

I gained my Industrial experiences from two organizations, CAD plus Innovations and Estate,

Works and Transport Department of Rivers State University of Science and Technology.

2.2.1 Skills Acquired in CAD plus Innovations

As part of the necessary tools in engineering Computer Aided Design (CAD) skill was an

achievement to me within the little time spent in this training. I was trained in the following

areas:

 AutoCAD 2D and 3D

 Inventor Professional software.

I was involved in many design projects such as: parts design and assembly a crane hoist, and

parts design and assembly of fruit juice extractor. Below are some pictures of the design

works.

23
24
Fig. 1.0 a crane hoist

2.2.2 ACTIVITIES PERFORMED IN ESTATE AND WORKS

As part of my Training in Estate and works department, I involved myself in many useful

activities within the establishment.

2.2.3 OPERATION OF POWER PLANT

In the Old site Power House operation of the Power Plants are the primary functions of the

operators. Whenever there is no power supply from the Port Harcourt Electricity Distribution

company (PHED) the need to put on the generator plants arises. There are certain steps to be

taken before the operation of the power plants. They are: checking

i. The Diesel level in the overhead tank

ii. Oil level in generator and

iii. The battery terminals if they are in contact with the terminal cables.

iv. If the plant’s circuit breaker is switched on.

After making sure that all these are in place, then the generator is set to run. The next step is

to turn on the Ignition key and allow for some few minutes say two (2) minutes or three (3)

minutes for the Electric Circuit Module (ECM) on the generator to come up by displaying the

engine parameters like the battery temperature, frequency and the engine speed etc. At this

point the engine is set to run by pressing the power button. To put off the generator takes the

reverse of the previous steps.

2.2.4 POWER DISTRIBUTION

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The power generated by the generator is transferred to the Incomer breakers on the ABB Low

Switch Gear panel and from the Incomer to the Bus Coupler circuit breaker which when

closed distributes current to the different breakers on the various sections of the panel from

where power is being distributed to the respective areas in the school by closing the circuits.
Opened switch (no flow of current)
Closed switch (flow of current hence
power distributed)

Llj

Direction of current from

Incomer circuit breaker

Fig.2.1 diagram showing the flow of current in the distribution panel

On each bar there are: Ammeter, Fault indicator light, Closed indicator light and Open and

Close switch. Also on the Incomer bus bar there are: Voltmeter, Ammeter scaled in kilo-

ampere, Open and Close switch and Indicator lights which show when the circuit is closed

and when there is fault on the circuit. The voltmeter reads the Incomer line voltages delivered

from the power source in Volts (V) while the Ammeter reads the incomer line currents in

Amperes (A).

26
 Open and Close switch

Bus bar Coupler

Distribution circuit
breaker

Ammeter on Incomer
light bar
indicator
Fault
Voltmeter on Incomer
bar

Open and Close

indicator light

Incomer circuit breaker

Fig.2.2 A sectional view of ABB LV SWGR showing its components.

2.2.5 BI-HOURLY LOGGING OF THE ACTIVITIES OF THE PANEL

One of my major daily activities in Old site Power house was the recording of the Incomer

lines voltages and currents and the power consumed by different sections of the school under

the Old site power station. The essence of taking the readings on the lines is to detect

whenever a particular line is overloaded or under loaded and also to avoid being over charged

by PHED for power consumed. Below is a sample of the record.

27
 LINE CURRENT (A) NEUTRAL- PHASE (V) PHASE-PHASE (V)

DATE SECTION TIME IL1 IL2 IL3 U1N U2N U3N UL12 UL23 UL31

Transformer (T1) 9:15am 300 200 490 220 220 220 370 370 370

Shopping complex 40

Hospital 150

Residential lecturers 200

03 -08 -2015

Vc’s office complex 40

Main office/hostel 60

Amphitheatre 50

Marine Engineering 0

Panel room 0

28
2.2.6 MAINTENANCE SERVICE OF 1275KVA AND 2000KVA AT OLD SITE

POWER HOUSE.

Every engine without periodic maintenance services may end up breaking down as well

reduce its life span. The both engines in Old Site power house are CAT products and

professionally they are supposed to undergo maintenance service after running for a

maximum of Two Hundred and Fifty Hours (250hrs) periodically. This is the major reason

why record of operations of the engines are noted each time they are being put on.

Steps Taking in Servicing the Power Plants

1. The plant was powered to run in idle mode for 5 – 10 minutes to heat up the oil in the

sump to make it lighter for easy drainage

2. Opening of the crankcase side pan with spanner of size 14mm to peep into the engine

to see if there was anything wrong with the connecting rod.

3. Opening of the fuel filter housing to remove damaged fuel filters and

4. Cleaning of the fuel filter housing by opening the priming pump and got the dirty fuel

primed out.

5. Replacement of the fuel filters with new ones. Note: in each of the generating plants

there are five (5) fuel filters and three (3) oil filters.

6. Closing of the fuel filter housing.

7. Opening of the bleeding knob and primed to eliminate gas and as well lift fuel back

into the fuel filter housing. Note: failure to do this, the engine start and shutdown. The

priming process continued until fuel came out of the bleeding knob indicating that

fuel has been lifted back into the fuel housing.

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Fig .2.3. Student priming to lift up diesel back into the fuel filter housing.
30
 8. Then replacement of the knob but not totally locked for some time to give room for

air escape and later locked.

9. Opening of the secondary water separator washed and replaced because it is metallic.

10. Opening of primary water separator attached to the overhead tank to drain off fuel and

water retained through the drain plug. Note: atmospheric pressure helps in the

draining.

11. Replacement with new water separator filter.

12. Opening of the oil filter housing. Note: the oil filter housing has no priming pump and

it is directly under the fuel filter housing.

13. Removal of the damaged oil filters and

14. Replacement of the oil filters with new ones and

15. Closing of the oil filter housing.

16. Drainage of engine oil from the sump or oil pan with the use of syphon pump.

Fig. 2.4. student draining engine oil from the sump of the generator.
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 17. Also the refilling of the engine oil with new one was done with manual syphon pump.

18. Refilling of coolant in the radiator of 1275kva generator. The type of coolant used

here was Extended Life Coolant (ELC). The coolant is a mixture of antifreeze

compound like glycol and antirust which resists the metallic parts of the engine from

reacting with water. After all these steps the plant was powered on for some time as a

test.

List of materials used.

1. Three drums of Diesel Engine Oil (DEO)

2. Ten (10) pieces of Fuel filters

3. Six (6) pieces of Oil filters

4. Two (2) pieces of primary water separator filters

5. Two (2) drums coolant (ELC)

Tools

Spanner, Ratchet, Syphon pump.

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2.3.0 OTHER MISCELLANEOUS ACTIVITIES PERFORMED
IN ESTATE COMPLEX

TRACTOR MAINTENANCE

Tractor, just like other diesel engines has three major systems: –

 The pure mechanical system

 Fuel system and

 The Electrical system.

Fig.2.4. serviced New Holland Tractor.

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FUNCTION OF DIESEL FUEL INJECTION

The fuel injection system lies at the very heart of the diesel engine. By pressurizing and

injecting the fuel, the system forces it into air that has been compressed to high pressure in

the combustion chamber.

The diesel injection system consists of:

 Fuel injection pump – pressurizes fuel to high pressure

 High-pressure pipe – sends fuel to the injection nozzle

 Injection nozzle – injects the fuel into the cylinder

 Fuel filter – filtrates the fuel

Some types of fuel tanks also have a fuel sedimentor at the bottom of the filter to separate

water from the fuel.

Functions of the system

The diesel fuel injection system has four main functions:

Feeding fuel

Pump elements such as the cylinder and plunder are built into the injection pump body. The

fuel is compressed to high pressure when the cam lifts the plunger, and is then sent to the

injector.

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Adjusting fuel quantity

In diesel engines the intake of air is almost constant, irrespective of the rotating speed and

load. If the injection quantity is changed with the engine speed and the injection timing is

constant, the output and fuel consumption change. Since the engine output is almost

proportional to the injection quantity, this is adjusted by the accelerator pedal.

Adjusting injection timing

Ignition delay is the period of time between the point when the fuel is injected, ignited and

combusted and when maximum combustion pressure is reached. As this period of time is

almost constant, irrespective of engine speed, a timer is used to adjust and change injection

timing – enabling optimum to be achieved.

Atomizing fuel

When fuel is pressurized by the injection pump and then atomized from the injection nozzle,

it mixes thoroughly with air, thus improving ignition. The result is complete combustion.

The Tractor uses electric injector pump which works directly from the ignition. As the

machine is ignited, current passes into the pump through the solenoid and open the valves for

fuel to pass through. This works with the amount of current delivered into the pump. In this

kind of injector pump, if the engine has electrical fault it will not start unless the solenoid is

removed.

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SYMPTOMS OF INJECTOR FAULT

These are some of the notable signs of diesel engine injector fault:

 Black smoke

 Hard starting

 Engine will not start

 Increase in engine temperature etc.

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CHAPTER 3

3.0 NEW SKILLS ACQUIRED

One of the objectives of SIWES is to get students acquainted with the daily happenings in the

industry or any establishment of attachment. For the period of my training with CADplus

innovations and the Estate and Works Department of Rivers State University of Science and

Technology, I have added new skills to my knowledge. Such as:

 Engineering design software

 autoCAD 2D and 3D

 inventor professional

 Operation of power plant (power generation)

 Distribution of power

 Maintenance service of CAT generator of 3500 series.

3.1 PROBLEMS ENCOUNTERED

Every good thing also has some challenges involved. Some of the problems I encountered in

the scheme are:

 Difficulty in securing a place to serve

 No proper care for I.T students

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CHAPTER 4

4.0 CONCLUSION

During the SIWES training I was exposed to different new things which are added

advantages to me now. The knowledge of CAD software packages like AutoCAD 2D and

3D, Inventor Professional design software were acquired during my first training in

CADPLUS INNOVATIONS.

Other experiences were gained in Estate, Works and Transport department where I was

trained on how to generate power and distribute power, regular visual inspection of the panel

bi-hourly and taking record of the power generation and consumption of the different sections

on the panel. Most paramount training I had was in the area of power plant maintenance

service, and tractor maintenance service.

4.1 RECOMMENDATIONS

SIWES is a good program for students to acquire knowledge that will be useful to them after

graduation. Hence, the Industries and Establishments should be made to understand that is

their responsibility to receive students for training than rejection in accordance with the

provisions of Decree No. 47 of 1971 in 2011.

Furthermore, there should also be proper care for students undergoing training, in areas like

 Provision of Personal Protective Equipment (PPE)

 Payment of allowance as to help in transport fares to place of attachment

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All these and many more if well improved on will make the scheme more successful and

profitable.

REFERENCES

 Students Industrial Work Experience Scheme (SIWES) hand book, November 2014

 Rivers State University of Science and Technology hand book.

 CAT Product Support Bulletin – How Diesel Engine Work and Wear

 www.denso-am.eu>diesel-components

 www.fire-Ready.com/fire-extinguishers

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