Chapter one

1.0 Introduction

1.1 SIWES

The Engineering discipline is practical in nature and mainly hinged on

experience. Hence there is great need for any student aspiring to be a

professional engineer to have some form of work experience while

studying at school, in a reputable engineering firm related to his/her course

of study. Students Industrial Work Experience Scheme (SIWES) is in

accordance with the federal government policy of technical education to enable

students to be exposed to the working experience in industries and to

enable them to be useful to their employers practically and not theoretically

alone. The Student’s Industrial Work Experience Scheme (SIWES) gives

students the opportunity to gain some relevant experience before leaving

the campus. The experience gotten by the students during the SIWES program

would enable them quickly fit into the industry upon graduation.

I had my work experience at the KSA Electrical Services Company Limited

(ZES), a subsidiary of SHELL, and an indigenous engineering firm. At ZES,

I learnt the fundamentals of electrical engineering; computer aided electrical

design, AutoCAD, and other relevant software such as Plant design management

system (a 3D drafting software), Chalmlite (a lighting design software). My

1
day to day activities at ZES were recorded in the log book.

1.2 KSA electrical services

KSA electrical services is a registered and well recognized electrical

company that has been in existence since 1990, it is a contractor company to

SHELL (SPDC) .KSA electrical services is a one man company owned by Engr

Emmanuel Okoro an electrical engineer. The company has the total numbers of 8

(eight) employees and 3 (three) contract staff, which are all professional in the

field of electrical and fire alarm. The company head office is located at KM.1

Ughelli Patani Road, Opposite Cosco Filling Station, Okuokoko, Warri, Delta

State.

1.3 Field of (business) activity/ responsibilities

KSA electrical services are into electrical wiring, electrical devices

installation, fire alarm installation and procurement of safety PPE (personal

protection equipment) materials.

1.4 Self concept

KSA electrical services company renders electrical services such as

domestic and industrial wiring, procurement of PPE (personal protective

equipment), safety materials, and electrical integrity testing such as continuity test,

insulation test and polarity test, as well as fire alarm devices installation to

companies, industries and individuals.

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CONTINUITY TEST: This is to ensure integrity of the live, neutral and earth

conductors without bridging (short circuit) of connection.

INSULATION TEST: this test is to ensure that there is a high resistance between

live and neutral conductors and these conductors and earth conductors, a low

resistance will result in current leakage and energy waste which could deteriorate

the insulation and be a potential fire hazard.

POLARITY TEST: this is to ensure that all switches and circuit breakers are

connected in the phase or live conductor.

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4
 Chapter two

Description of attachment

2.1 SIWES workplace (KSA's Profile)

KSA's history

KSA electrical services is a registered and well recognized electrical company

that has been in existence since 1990, it is a contractor company to SHELL

(SPDC) .KSA electrical services is a one man company owned by Engr Emmanuel

Okoro, an electrical engineer. The company has the total numbers of 8 (eight)

employees and 3 (three) contract staff, which are all professional in the field of

electrical and fire alarm. The company head office is located at KM.1 Ughelli

Patani Road, Opposite Cosco Filling Station, Okuokoko, Warri, Delta State.

And has branches at SHELL Residential Area, Aba Road, Port Harcourt and

SHELL Industrial Area, old Aba Road, Port Harcourt.

Vision

"To be a world class Engineering Company."

Mission

"To provide world class engineering services in the oil and gas industry."

Quality Policy

"To satisfy and strive to exceed customer requirements through

continuous demonstration of quality and active participation of all employees".

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2.1.2 KSA's Departments

The various departments in KSA and their functions with respect to project

execution are:

Technical Departments

• Engineering: - It is the heart of KSA. Preparation of engineering design and

studies.

• Project Controls: - Project planning and scheduling, cost estimating, cost

engineering and information technology.

• Projects: - Co-ordinates the engineering activities being undertaken during any

project including arranging for site visits, liaison with the customers to inform

them about the progress of their projects. Management of all capital projects.

• Procurement: - Management of procurement function for operations. Provides

materials needed by the other departments and keeps stock of what is available

in the stores at any point in time.

• Construction: - Management of construction activities.

• Training: - Organize/arrange staff development programs like on-the-job-

training, short- term courses and seminars, overseas rotational training etc, to

ensure that KSA's personnel are informed of technological advancement in the

industry. It ensures employee development.

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2.1.2 Fire alarm department

Fire alarm department of KSA ELECTRICAL SERVICES COMPANY is a

department with the total numbers of four (4) staff. This department is directly in

charge of fire alarm devices equipment installation, fire safety equipment

installation, such as fire extinguishers, fire call point etc. this department is also in

charge of procurement, supply of PPE (personal protective equipment) materials

and fire safety devices .

2.1.3 Electrical department:

Electrical department of KSA ELECTRICAL SERVICES COMPANY is a

department with the total numbers of four (4) staff. Electrical department is

directly in charge of electrical domestic and industrial wiring, electrical devices

installation, electrical integrity testing and procurement/supply of electrical

materials such as cables, lighting fittings and power equipment such as industrial

sockets, water heaters, and electronics equipment such as cctv cameras

2.1.4 KSA's experience

Since its inception, KSA has executed more than 100 projects of

varying magnitude and cost implications. Among these projects are:

• Installation and maintenance of FM200 smoke detector and fire alarm panel

at SPDC west

• Installation and maintenance of fire alarm panels at SPDC west.

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• Conceptual design for the Cawthorne Gas injection/supply project for Shell.

2.2.1 Task description

Troubleshooting: this is the process of tracing to rectify fault that the cause is

unknown .i.e. if some lighting in a circuit are not lighting while others in the same

circuit are working, first you test the lighting point of the once that are not working

to see if there is supply, if there is current in both live and neutral conductors you

will know that the neutral has cut off at a point, and it is known as short circuit.

Electrical wiring: this is the networking system or arrangement of cables for the

free flow of current in a circuit.

2.2.2 Type of wiring

(1) CONDUIT WIRING: this is the process whereby electric cables are

arranged systematically in a wall through the use of PVC pipe in order to

transfer energy from one point to another in a circuit.

(2) CLEAT WIRING: this is a system of wiring done in an industry with the

help of a cleat chip made of different types of groove.

INTEGRITY TEST: this is the process of testing completed electrical

installations to verify that the system will operate efficiently and safely. The tests

are extensive, as defined in the institution of electrical engineers regulations. They

can only be carried out by a competent person, i.e. a qualified electrician or

electrical engineer.

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THE FOLLOWING TESTS ARE AN ESSENTIAL PART OF THE

PROCESSINGS

(1) DEAD TEST: - this is the process of testing completed installations without

power supply. The aim is to test the continuity to ensure integrity of the

live, neutral and the earth conductors without bridging (short circuit).

Testing the insulation to ensure that there is a high resistance between live

and neutral and earth conductors. Testing polarity to ensure all switches and

breakers are connected to phase, live conductors.

(2) LIVE TEST this is the process of testing completed installation with power

supply. The aim is to know the load that is connected to each circuit, each

phase and entire 415v that is supplied. During this test we also test for earth

loop to know the effectiveness of the installation earthling system.

Integrity test is undertaking by visual inspection and the use of a

multipurpose meter (multimeter) or an instrument specifically for recording

resistance i.e. an ohmmeter or megger.

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 Chapter three

3.1 The electrical group

Usually, a typical project begins in the process group with the conceptual or

basic design. The process group develops the initial block diagrams, evaluates all

the options, and proposes the best alternative for the project.

Other disciplines (Electrical group inclusive) will then work on what the process

group has put down.

3.1.1 Roles of the electrical group

On any project, the Electrical group is concerned with the following:

 To design a system that delivers energy or electricity to utilization points.

 To design a system that is reliable, economical and operationally flexible.

 To ensure that the system designed is safe for both personnel and equipment.

3.1.2 Electrical group activities

To achieve the above objectives, the following activities are usually carried

out by the electrical group:

 Develop design criteria.

 Formulate power generation/distribution philosophy.

 Carry out load shedding and/or sharing duties.

 Carry out transient and earth fault condition analysis.

 Develop electrical equipment specifications.

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 Carry out electrical equipment sizing and selection.

 Prepare material requisition (MR) and Bill of Quantities (BOQ) for

electrical equipment.

 Technical bid analysis.

 Produce electrical deliverables.

3.1.3 Electrical group deliverables

Deliverables are documents produced by a group with respect to the scope of the

project. The deliverables produced by the electrical group are: -

 Single line diagrams

 Electrical layout drawing

 Schematic and interconnection drawings

 Hazardous area classification

 Material Requisition (MR)

 Supplementary Drawing

 Data sheets

 Cable schedules

 Installation details

 Specifications

3.1.4 Computer software

Used by the Electrical group are: -

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 AutoCAD

Plant Design Management System (PDMS)

Microsoft Excel

Microsoft Word

Chalmlite

Multisim

3.2 Skills and practices acquired as an industrial trainee

As a student under the SIWES at KSA, I was exposed to standard

Engineering design practices. The projects executed at KSA ensured that Engineers

worked in teams, hence, I was taught to be a team player, and a good one at that. I

received training in the following areas of electrical engineering practice:

1. Computation of Load list:

This is one of the starting point for the electrical group activities.

For any given project, it is important to know the specific number of

electrical loads on site. This is to ensure adequate sizing of power sources,

cables, distribution boards etc. I learnt how to compute a load list, which is

usually a Microsoft Excel document showing all intended loads, their tag

numbers, current, voltage and power ratings, efficiencies, power factors, and

service duty.

2. Generation of single line diagrams:

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There were many instances where I was required to develop one or single line

diagrams. The electrical load list came in very handy in such instances.

A single line diagram is a schematic drawing that uses graphical symbols and

standard nomenclature to illustrate the overall configuration of an electrical

system. The single line diagram shows diagrammatically the conceptual/detailed

design for power generation and distribution on a site, interconnections between

various loads, Generation philosophies, load layouts, busbars and their respective

voltage levels, system protection devices, amongst others. These are well shown on

single line diagrams with standard electrical symbols. I received extensive training

on the use of autoCAD, which is the software used by the electrical group to draw

one line diagrams. Figure 3 below shows a single line diagram which I drew with

the aid of autoCAD for the R.A Club Kitchen, whose load summary is shown in

Figure 3.1

Fig. 3.2

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3. Equipment sizing and Cable sizing

Areas covered here include Generator sizing, Transformer sizing, circuit breaker

sizing, and cable sizing calculations. I also learnt about the relevant standards and

codes as regards equipment sizing and cable selection, such as the National

Electric Code (NEC), and the National Electric Manufacturers Association

(NEMA) codes.

As part of my training, I was given an assignment on equipment and cable sizing in

the R.A Club kitchen equipment project. The calculations I carried out are shown

below:

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CALCULATIONS

SIZING OF EQUIPMENT IN THE CLUB KITCHEN PROJECT

SIZING OF TRANSFORMERS AND GENERATORS

FORMULA USED:

GEN. SIZING:

RUNNING LOAD (RL) = TOTAL CONTINUOS LOAD +30%

INTERMITTENT LOAD.

PEAK LOAD (PL) = RUNNING LOAD +20% STANDBY LOAD.

TRANSFORMER SIZE  I.25 *PEAK LOAD.

ASSUMPTION: USING N+1 PHILOSOPHY.

TRANSFORMER SIZING≅ GENERATOR SIZING.

GENERATOR SIZING (USING N+1 PHILOSOPHY)

RL = 30691.65 + (0.3*1524.18) = 31148.90 KVA

PL = 31148.90 +70.60 = 31219.56 KVA

FUTURE EXPANSION = 25%

PL = 1.25*31219.56 = 39024.45 KVA

FOR N + 1 GEN.; WHERE N = 2

PL/2 = 19512.25 KVA

GENERATOR SIZE = 3 Nos. 20 MVA GENERATOR.

TRANSFORMER SIZING:

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T1 (11\ 33 KV)

RL = 30,000 KVA

PL =30,000 KVA*1.25 =37,500 KVA

T1 SIZE = 37.5 MVA.

T2 (11\6.6 KV)

RL = 414 KVA

PL = 414*1.25 = 517.5 KVA

T2 SIZE = 750 KVA.

T3 SIZE (11\0.4 KV)

RL =336.25 + 16.5 =352.75 KVA

PL = 352.75* 1.25 = 440.94 KVA

T3 SIZE = 500KVA

T4 SIZE (11\0.4 KV)

RL =336.25 + 16.5 =352.75 KVA

PL = 352.75* 1.25 = 440.94 KVA

T4 SIZE = 500KVA

T5 SIZE (11\0.4 KV)

RL = 355.4 + 26.75 = 282.15 KVA

PL = 382.15 + 70.60 = 452.75 KVA

452.75*1.25 = 565.94 KVA

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T5 SIZE = 750 KVA

T6 SIZE (11\0.4 KV)

RL = 355.4 + 26.75 = 282.15 KVA

PL = 382.15 + 70.60 = 452.75 KVA

452.75*1.25 = 565.94 KVA

T6 SIZE = 750 KVA

CABLE SIZING:

FORMULA USED:

I = P / (3*V) AMP + 25% I (future expansion)

GENERATOR CABLE SIZING:

I = 20MVA / (3*11KV) = 1049.73 * 1.25 = 1312.15A

CB SIZE: 1200A

CABLE SIZE:

TRANSFORMER CABLE SIZING:

T1:

PRIM: I = 37.5MVA / (3*11KV) = 1968.24A * 1.25 = 2450.3A

CB SIZE: 2000A

CABLE SIZE:

SEC: I = 37.5MVA / (3*33KV) = 656.08A * 1.25 = 820.10A

CB SIZE: 700A

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CABLE SIZE:

T2:

PRIM: I = 750KVA / (3*11KV) = 39.36A * 1.25 = 49.20A

CB SIZE: 40A

CABLE SIZE:

SEC: I = 750KVA / (3*6.6KV) = 65.61A * 1.25 = 82.01A

CB SIZE: 70A

CABLE SIZE:

T3:

PRIM: I = 500KVA / (3*11KV) = 26.24A * 1.25 = 32.80A

CB SIZE: 30A

CABLE SIZE:

SEC: I = 500KVA / (3*0.4KV) = 721.69A * 1.25 = 902.11A

CB SIZE: 800A

CABLE SIZE:

T4

PRIM: I = 500KVA / (3*11KV) = 26.24A * 1.25 = 32.8A

CB SIZE: 30A

CABLE SIZE:

SEC: I = 500KVA / (3*0.4KV) = 721.69A * 1.25 = 902.11A

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CB SIZE: 800A

CABLE SIZE:

T5 = T6

PRIM: I = 750KVA/ (3*11KV) = 39.37 * 1.25 = 49.21A

CB SIZE: 40A

CABLE SIZE:

SEC: I = 750KVA/ (3*0.4KV) = 1366.63 * 1.25 = 1708.27A

CB SIZE: 1600A

CABLE SIZE:

These current values are also used for sizing the transformer and generator CBs.

CABLE AND CIRCUIT BREAKER SIZING FOR LOADS

Formula used:

I = P/ ((3*V)

Type of cable: PVC insulated, armoured, installed in air.

BUS A:

Four starter motors

I = 7500KVA/ ((3*33KV) = 131.2A * 1.25 = 164A

CB = 150A

Cable size = 70mm 2 PVC, ARMOURED

BUS B:

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Generator starter motor

I = 690KVA/(3*6.6KV) = 60.4A *1.25 = 75.5A

CB= 70A

CABLE SIZE = 35mm2

BUS C:

I = 55KVA/(3*0.4KV) = 79.39A*1.25 = 99.2A

Wharf burner fuel 1 & 2

CB: 80A

Cable size: 35mm2

Bunker fuel heating load

I = 162.5KVA/(3*0.4KV) = 234.6A *1.25

= 293.2A

CB: 250A

Cable size: 185mm2

BUS D:

Causeway lighting

I = 18.4 * 1.25 = 22.55A

CB: 20A

Cable size: 2.5 mm2

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HVAC supply

I = 27.06 * 1.25 = 33.83A

CB: 30A

Cable size: 6 mm2

Office and Amenities

I = 126.30A * 1.25 = 157.88A

CB: 150A

Cable size: 70 mm2

BUS E:

UPS

I = 7.22A *1.25 = 9.03A

CB: 15A

Cable size: 1.5 mm2

Warehouse supply 2

I = 10.83A * 1.25 = 13.5A

CB: 15A

Cable size: 1.5 mm2

Obstruction lighting

I = 1.80A * 1.25 = 2.25A

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Cable size: 1.5 mm2

CB: 15A

Warehouse supply 1/ Wkshop supply

I = 32.46A * 1.25 = 40.6A

CB: 35A; cable size: 6 mm2

Gate house supply

I = 18.04A *1.25 = 22.6A

CB: 25A

cable size: 2.5 mm2

BUS F

P1 = P2

CB: 125A

CABLE SIZE: 35 mm2

P3 = P4

CB: 50A

CABLE SIZE: 10 mm2

P5 = P6

CB: 125A

CABLE SIZE: 70 mm2

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P7 = P8

CB: 300A

CABLE SIZE: 185 mm2

P9:

CB: 15A

CABLE SIZE: 1.5 mm2

P10, P11, P12:

CB: 15A

CABLE SIZE: 1.5 mm2

4. Electrical Layout drawings (Earthling, Cable, and Lighting layout):

An electrical layout drawing gives a plan view of an area (e.g a Flow station), and

shows by means of appropriate sign conventions, such features as the

earthing grid(earthing layout), electrical cable route(cable routing layout),

location of lighting towers/fixtures(lighting layout) etc. I was trained on how to

draw layout drawings using auto CAD. I learnt about the various factors to be

considered before layout drawings/designs are produced.

5. Hazardous Area classification/drawings:

I was also trained on how to produce hazardous area drawings using autoCAD. A

hazardous area is a three-dimensional space in which a flammable atmosphere may

be expected to be present at such frequencies as requires special precautions for the

23
construction and use of all electrical apparatus. The purpose of these drawings is to

provide assistance in selecting the correct certified equipment for hazardous zones

(as will be clearly noted on the drawing) such as petrochemical plants, refineries,

gas plants, oil terminals, etc.

6. Supplementary drawings (Cable schedules, Distribution board schedules,

Schematics and Interconnection drawings, Installation details, Specifications):

These drawings are also produced at later electrical design stages for a project. I

was also opportune to see how these drawings were produced and their relevance

to the project. The training I received involved the use of the following

computer aided design/application software:

• AutoCAD

• Chalmlite software for lighting design and calculations)

• Plant design Management system (PDMS).

AutoCAD

It is a computer aided drawing software. It is used by the electrical group to draw

single line diagrams, electrical layout drawings, hazardous area drawings,

distribution board schedules, schematics and interconnection diagrams, power

layouts etc. The AutoCAD design package is a general purpose software. It is an

extremely powerful tool. The speed and ease at which a drawing can be prepared

and modified using a computer offers a phenomenal advantage over hand

24
preparation. There is virtually no limit to the kind of drawings that can be

prepared using the software. AutoCAD provides a set of entities for use in

constructing a drawing. An entity is a drawing element such as a line, circle, or text

string annotations. The effect of every change appears immediately, thus enabling

the designer to take immediate decisions concerning size, aesthetics and taste of

the designer. Other AutoCAD functions allow modifications of the drawing in

a variety of ways e.g. erasing or moving entities or copying them from repeated

patterns.

The view of the drawing displayed on the screen can be changed, or

information about the drawing can be displayed. The use of layers and assigning

colours to the different layers enhances the appearance of the end product and aids

in detecting errors in the drawing that would otherwise have gone undetected. The

final drawing can then be plotted with a pen plotter or printer plotter. The

importance of this software can be more appreciated in that is saves time and cost

in the production of drawings, by providing the engineer with a mature tool to

work, thus, ensuring a more professional and accurate output. The activities of the

electrical group to which to which I was attached, involved the extensive use of

AutoCAD.

3.2.1 Skills acquired

By virtue of the training I received and exposure, I have acquired the following

25
skills from the SIWES workplace (i.e. KSA):

i. Proficiency in the use of AutoCAD.

ii. Proficiency in the use of Microsoft EXCEL for the development of

spreadsheets.

iii. Ability to use chalmlite to carry out lighting design and calculations.

iv. Ability to use Plant design Management System (PDMS) - a 3D

drafting software.

v. Ability to work effectively in a team, and to communicate effectively with

others.

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 Chapter four

4.1 Summary

The purpose of this SIWES program is to bridge the gap between classroom

and the industries so that student will be well prepared for the task ahead after their

schooling. So this 6months SIWES program has expose me to real Electrical

Installation works, it has really help me to bridge the gap between the classroom

and the industry, this industrial training really gave me an insight to the task that

lies ahead of me in my chosen career “Electrical Engineering”. So this Industrial

Training Report is aimed to picture the various task that is being carried out in the

industry on the field of Electrical Engineering, the skill acquired and the challenges

on the aspect of Innovation and Creation in order to make the world a comfortable

place for humans.

4.2 Recommendation

 I will advise that more Electrical engineering students be posted to the

organization for their SWEP and SIWES.

 Also, the ITCC should find a way to liaise with the company that students

on IT be given transport allowance or there should be provision of a staff

27
 bus for the students, being an example I spent an average of 500 naira daily

during the course of the IT.

 The ITCC should also ensure frequent visit of supervisors to the companies

where students are posted so as to enable students to be serious minded for

the duration of the IT.

 Students should be posted on time to ensure that there is time to get enough

knowledge of what they should learn at their respective workplace.

 The main essence of the scheme should be made known to the companies, so

that students are not assigned to tasks that are not of benefit to his/her career

development.

4.4 Conclusion

The SIWES has positively contributed to my training as a future

Electrical/Electronics Engineer. At the SIWES workplace (i.e. KSA), I was able to

reconcile theoretical principles learnt in school with real Electrical/Electronics

engineering design practice. I also learnt various software applications relating to

my discipline such as AutoCAD, Microsoft EXCEL, Microsoft Word, etc.

Furthermore, I received extensive training on electrical design fundamentals

which included the following: Development of load and single line diagrams,

Design of electrical layout drawings (cable, earthing and lighting layout

drawings), Hazardous area classification drawings, Equipment sizing, cable

28
and circuit breaker sizing, preparation of material take- off and bill of

quantities, lighting design/calculations, and schematic/interconnection drawings.

SIWES gave me the opportunity to learn about good work ethics, good

interpersonal and communication skills.

29
 References

www.shell.com.ng/aboutshell/at-a-glance.html

Harrison Inspection and Training (Nig) ltd. Electrical Installations and systems.

Strathmore University, Attachment Report Guidelines APO-02-03-11/10

Engr. Okoro Emmanuel, Director KSA Electrical Services.

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 APPENDIX

As Built Drawings

Power Layout Drawings

Lighting Layout Drawings

Load Balancing Drawings

Load Schematic Diagrams

31