FEDERAL UNIVERSITY OF TECHNOLOGY

P.M.B.1526 OWERRI

A REPORT ON

STUDENT INDUSTRIAL WORK EXPERIENCE

SCHEME (SIWES) 400 LEVEL

DONE AT

NIGERIAN PORT AUTHORITY

P.M.B 4053 RIVERS PORT COMPLEX

DONE BY

ATUOMA ALOZIE ALEXANDER

20191151405

SUBMITTED TO

DEPARTMENT OFMECHAN ICAL ENGINEERING

IN PARTIAL FULFILMENT OF THE REQUIREMENTS FOR

THE AWARD OF THE BACHELOR DEGREE (B. Tech) IN SCHOOL OF

BIOLOGICAL SCIENCES

MAY, 2024

DEDICATION

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This report is dedicated to Almighty God who has been all merciful to bring me to this stage of
my life. He has been with me and carried me all the days of my life, especially during my
Industrial Training period. He is the reason why I have content to write in this report.

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 ACKNOWLEDGEMENT

I want to thank God who gave me strength and endurance throughout this IT period.

Also, to my parents, Mr and Mrs Ibeako who made sure I was comfortable, by providing all I
needed to keep up during the industrial training, thanks.

I sincerely want to thank Dr. Mustapha and Dr. Dauda who were the heads of the two sections
where I did my IT in NIGERIA PORT AUTHORITY, Thank you for taking me through all that I
am supposed to know in your sections.

I also want to thank Mrs. Otti, for the love and all the training she gave me during my stay in the
general laboratory.

I also want to acknowledge my able HOD. Prof. Linus, A. Nwogu and my Course Adviser, Mr
Thaddeus Onyebuchi Ukwueze, my department SIWES coordinator, and my university-based
supervisor Dr. Mrs Ifeyinwa.

Finally, I want to acknowledge the university management for establishing this framework for
the Industrial Training Program, and making it compulsory as it helped students gain quality
practical knowledge in their various fields.

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 TABLE OF CONTENTS

Title page

Dedication

Acknowledgement

Table of contents

CHAPTER ONE

INTRODUCTION

1.0 Students Industrial Work Experience Scheme

1.1Brief History of SIWES

1.2 Benefits of SIWES

1.3 Objectives of SIWES

CHAPTER TWO

2.0 History of Nigerian Port Authority

2.1 Historical background of Nigerian Port Authority

2.2 Organisational Address of Nigerian Port Authority

2.3 Vision of Nigerian Port Authority

2.4 Mission of Nigerian Port Authority

2.5 Equipment, Tools used in the laboratory

2.6 Basic roles of the laboratory scientists in Nigerian Port Authority

CHAPTER THREE

3.0 Industrial training Experience

3.1 Equipment and Material Testing Laboratory

3.2 Safety and Precautions in The Laboratory

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3.3 Instrumentation

3.4 Test carried out in the laboratory

3.4.1 Blood sugar Test

3.4.2 Hematology Test

3.4.3 Blood grouping Test

3.4.4 Malaria Parsite Test E.t.c

CHAPTER FOUR

4.0 Challenges Faced During the Period of Industrial Training

4.1 Conclusion

4.2 Recommendation To SIWES

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 LIST OF FIGURES

Fig 3.1: Electric weighing balance 17

Fig 3. Universal testing machine 17

Fig 3.1.2 Fume cupboard 17

Fig 3.1.3 Electrophoresis machine 17

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 CHAPTER ONE

STUDENTS INDUSTRIAL WORK EXPERIENCE SCHEME (SIWES)

1.0 INTRODUCTION TO SIWES

The Students Industrial Work Experience Scheme (SIWES) is the accepted skills training
programme, which forms part of the approved minimum Academic Standards in the various
degree programmes for all the Nigerian Universities. It is funded by the Federal
Government of Nigeria and jointly co-ordinate by the Industrial Training Fund (ITF) and
the National Universities Commission (NUC).

It is also designed to expose and prepare students of Universities, Polytechnics, Colleges of

Technology, Colleges of Agriculture and Colleges of Education for the industrial work
situation they are likely to meet after graduation. The scheme also affords students the
opportunity of familiarizing and exposing themselves to the needed experience in handling
equipment and machinery that are usually not available in their Institutions. Before the
establishment of the scheme, there was a growing concern among our industrialists that
graduates of our Institutions of higher learning lacked adequate practical background studies
preparatory for employment in Industries. Thus, the employers were of the opinion that the
theoretical education going on in higher institutions was not responsive to the needs of the
employers of labour. It is against this background that the rationale for initiating and
designing the scheme by the Industrial Training Fund (ITF) during its formative years –
1973/74 was introduced to acquaint students with the skills of handling employers’
equipment and machinery. The ITF solely funded the scheme during its formative years. But
as the financial involvement became unbearable to the Fund, it withdrew from the Scheme
in 1978. The Federal Government handed over the scheme in 1979 to both the National
Universities Commission (NUC) and the National Board for Technical Education (NBTE).
Later the Federal Government in November 1984 revert the management and
implementation of the SIWES Programmed to ITF and it was effectively taken over by the
Industrial Training Fund in July 1985 with the funding being solely borne by the Federal
Government .

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1.1 MEANING OF SIWES.
The Student Industrial Work Experience Scheme (SIWES) is the skill training program, which
constitutes the approved minimum academic standard in the various degree programs for all tertiary
institution in Nigeria. It is the gateway between the practical aspects and theory aspects of either
engineering and science technology and other professional educational programs in Nigerian tertiary
institution. It is a planned and supervised training intervention based on stated and specific learning and
career objectives geared towards developing the occupational competencies of the participants.

1.2 PURPOSE OF SIWES

The purpose of Student Industrial Work Experience Scheme (SIWES) is to enable every student
who passed through the university or other institutions to acquire a practical knowledge of what
he/she has learned. Therefore, it is compulsory for every student to satisfy the requirement in
his/her academic pursuits. It also affords the students the opportunity of familiarizing and
exposing themselves to the needed experience in handling equipment and machinery that are
usually not available in their institutions

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 1.3 AIMS AND OBJECTIVES

Specifically, the objectives of the Students Industrial Work Experience Scheme (SIWES)
are to:
 Provide an avenue for students in institutions of higher learning to acquire industrial
skills and experience in their course of study, which are restricted to Engineering and
Technology including Environmental studies and other courses that may be
approved. Courses of NCE (Technical), NCE Agriculture, NCE (Business), NCE
(Fine and Applied Arts) and NCE (Home Economics) in Colleges of Education are
also included.
 Prepare students for the industrial work situation they are to meet after
graduation.

 Expose students to work methods and techniques in handling equipment and

machinery that may not be available in their institutions.
 Make the transition from school to the world of work easier, and enhance
students’ contacts for later job placement.
 Provide students with an opportunity to apply their knowledge in real
work situation thereby bridging the gap between theory and practice.
 Enlist and strengthen employers, involvement in the entire educational process
and prepare students for employment in Industry and Commerce.
 Provide students the opportunity to develop attitudes conducive to
effective interpersonal relationships.
 Ernest placement and strengthen employees involvement in the educational
process of preparing student for employment in industries.

1.3 Roles of Students in SIWES Programme

1) To attend the institution’s SIWES orientation program before going on attachment.

2) To be obedient to constituted authorities and adhere strictly to all the rules and
regulations of the organization to which students are attached.

3) To be regular and punctual at respective places of attachment’

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4) To avoid change of place of attachment, except in special circumstances which must be
determined and approved by their institutions’ supervisors, the employer, and the ITF?

5) To complete the SPE-1 form and get it endorsed by the employer for onward submission
to ITF.

6) Record all training activities and other assignments in the logbook and ITF form 8 to
ensure proper assessments.

7) To attend the institution’s SIWES orientation program before going on attachment.

1.4 IMPORTANCE OF SIWES

1. It provides students with an opportunity to apply their theoretical knowledge in real life
situations.
2. It exposes students to more practical work methods and techniques.
3. It strengthens links between the employers, universities and industrial training fund
(ITF).
4. It also prepares the students for the labour market after graduation.

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 CHAPTER TWO

NIGERIAN PORT AUTHORITY (N.P.A)

2.0 HISTORY OF NIGERIAN PORT AUTHORITY

I was privileged to work with the Nigerian Ports Authority Rivers Port Complex Port Harcourt,
aligning with the program’s objective.

Nigerian Port Authority is a Federal Government Agency that governs and operates the ports of
Nigeria. The major ports controlled by the NPA includes: the Lagos Port Complex and Tin Can
Island Port in Lagos, Calabar Port, Delta Port, Rivers Port at Port Harcourt, and Onne Port. The
operations of the NPA are carried out in affiliation with the presidency of (Nigerian) and the
Nigerian Shippers Council. The head office of the NPA is located in Marina, Lagos. The NPA is
Maritime Company that provides and operates necessary facilities in ports and maintains,
improves and regulates the use the ports and provides for matters connected therewith. The Port
serves as a medium to import and export of goods including refined petroleum, AGO, Gypsum
in bulk, salt in bag, naphtha, frozen fish, bagged cement, lead/zinc, wheat grain, sugar, malt,
crude oil, bitumen, caustic soda, butane, chemicals etc. through cargos.

2.1 HISTORICAL BACKGROUND OF THE COMPANY

The Nigerian Ports Authority, was established as a continuous Public Corporation by the Ports
Acts in the year 1954 to address the institutional weakness that bordered on lack of coherent
policy framework as ports development were done and driven by changes on the level and
demand of sea-borne trade.

2.2 ORGANIZATIONAL ADDRESS

Nigerian Ports Authority, Calabar Port Complex islocated 288C+96F, Harbour Rd, Ikot Mbo
Rubber Esta, Calabar,Cross Rivers State, Nigeria.

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2.3 VISION OF NIGERIAN PORTS AUTHORITY.

Nigerian Ports Authority, Rivers Port Complex envisions to be the leading Port in Africa.

MISSION OF NIGERIAN PORTS AUTHORITY.

To deliver efficient port services in a safe, secure and customer-friendly environment.

2.4 ORGANOGRAM OF NIGERIAN PORTS AUTHORITY.

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2.5 DEPARTMENTS IN THE ESTABLISHMENT AND THEIR FUNCTIONS

Harbours Department:

 Responsible for the pilotage services, safe berthing and un-berthing of ships.

 Training and licensing of marine pilots.

 Handling and maintenance of the Authority’s water crafts and vessels traffic
control.

Vessels Management/ Dockyard Department:

 Specializes in the repairs and maintenance of the Authority’s vessels/crafts.

Hydrography Department:

 Responsible for the supervision, participation and deepening of the bonny channel
and river.

Environment Department:

 Responsible for primary duty to ensure that the port operators comply with
environmental laws governing their various operations.

 Regulation of environmental surveillance on terminal and jetties.

Traffic Department:

 Supervision of the water supply to vessels on request during the review period.

 Responsible for the registration of shipping agents/ companies after complying

with the necessary requirement.

Tariff and Billing Department:

Ensures revenue was gained by raising bills on all legitimate operations in the port.

Fire Service Department:

 Responsible for fire prevention, protection and operation.

Safety Department:

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  Responsible for the monitoring and ensuring implementation of a safe system of
work for improving health and safety of personnel and properties in Rivers Port.

Security Department:

 Responsible for the protection of lives and properties of the organization.

Accounts Department:

 Handles all the revenue collected and operating expenditures in the port.

Stores Department:

 Responsible for the receiving of goods in the port.

Procurement Department:

 Procuring materials necessary for the proper and effective running of the port.

Internal Audit:

 Responsible for monitoring bills certified for payment.

 Witnessing of purchase and certification of goods received.

Enterprise Risk Management Department:

 Responsible for the monitoring of concessionaries.

 Plays advisory roles to officers and staff on insurance related matters.

Human Resources and Administration Department:

 Responsible for the employee strength

Legal Department:

 Responsible for contractor’s registration, agreement, legal opinions and litigation.

Training Department:

 Responsible for the training and re-training of officers and staff, laying emphasis
on security and safety.

Medical Department:

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  Responsible for preventive health care to all the employees.

Corporate and Strategic Communication Department:

 Creates cordial relationship between Management and the public

 Hosting community matters, planning adverts etc.

Corporate and Strategic Planning Department:

 The databank of the Port.

 Responsible for the generation of data and information.

Engineering Department:

 Responsible for monitoring developmental projects and infrastructural

maintenance.

Estate Department:

 Responsible for jetty inspections, demand notes etc.

2.5 ROLES OF ENGINEERING DEPARTMENT IN NPA

1. Infrastructure Maintenance and Development: The engineering department at the Nigerian
Ports Authority oversees the maintenance and development of crucial port infrastructure like
terminals, berths, and navigational channels. Their role ensures these facilities are in optimal
condition to facilitate efficient vessel operations and cargo handling.

2. Equipment Maintenance and Repair:

Engineers in the department are responsible for the regular maintenance, repair, and servicing
of port equipment such as cranes, conveyors, and container handling machinery. Their efforts
contribute to the reliability and longevity of equipment critical to port operations.

3. Safety and Environmental Compliance:

Ensuring adherence to safety regulations and environmental standards is paramount. The
engineering department implements rigorous safety protocols to safeguard personnel and assets,
while also implementing measures to minimize environmental impact from port activities.

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4. Planning, Innovation, and Training:
The department plays a key role in planning and designing future port expansions and
improvements. They integrate advanced technologies and innovations to enhance operational
efficiency and capacity. Additionally, they provide training to personnel, ensuring skills
development and readiness to manage emergencies and maintain operational excellence.

CHAPTER THREE

INDUSTRIAL TRAINING EXPERIENCE

During my industrial training process at the NIGERIAN PORT AUTHORITY , I was a trainee student
at the Engineering department.
The department majors on maintenance,installation and any other technically inclined operation in the
caalabar port.
I was opportune to have basic knowledge on how to manage the port diesel engine,servicing of the
engine,do some basic installation carry out some basic electrical repairs, I was also taught the basic
rules and regulations, safety measures and safety equipments needed In the engineering workspace.

3.0 SECTIONS I CARRIED OUT MY INDUSTRIAL TRAINING

1. Port power house

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2. Installations in port

3.1 PORT POWER HOUSE

The power house of Nigerian Ports Authority is a section under the engineering department that
is saddled with the responsibility of providing electricity for the port. The following are the
components/sections of the power house;
1. The engine room/ diesel engine
2. The changeover room
3. The power house office

3.2 DIESEL ENGINE/ENGINE ROOM

3.2.1 THE ENGINE

An engine is a machine that takes one form of energy and turns it into mechanical force or
motion. The most familiar examples are combustion engines that burn fuel to power vehicles like
cars and lawnmowers. But engines come in many varieties, from electric motors in appliances to
giant jet engines in airplanes.
IMPORTANCE OF ENGINES
Engines are fundamental for many things in our world, especially when it comes to
transportation. Here's why they are so important:

1. Power source: An engine's main function is to convert energy, typically from fuel, into mechanical
energy that can be used to power machines. This mechanical energy is crucial for transportation as it
allows vehicles to move . Imagine a car - without a functioning engine, it would be nothing more than a
metal shell.
2. Efficiency and performance: A well-maintained engine can significantly impact a vehicle's
performance and efficiency. Regular maintenance can help your car run smoother, use less fuel, and
emit fewer pollutants
3. Lifespan of machines: Engines are often complex and expensive to replace. Proper care and
maintenance can extend an engine's lifespan, saving you money in the long run .This applies to cars, but
also other machinery that relies on engines.

3.2.2 TYPES OF ENGINES

Engines can be categorized in a few different ways, but two main breakdowns are by combustion type
(internal vs external) and by cycle (number of strokes). Here's a look at some common types:

By Combustion Type:

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 Internal Combustion (IC) Engines: These engines burn fuel directly inside a closed chamber
(cylinder).expand_more The hot expanding gases from combustion push a piston, which creates
the mechanical work.expand_more There are two main sub-categories:

o Spark Ignition (SI) Engine: These engines, commonly used in

gasoline-powered vehicles, mix fuel with air before igniting it with a
spark plug.expand_more The four-stroke cycle is the most common
design for SI engines, involving Intake, Compression, Power, and
Exhaust strokes
o Compression Ignition (CI) Engine: Also known as diesel engines,
these engines use high compression to ignite the fuel instead of spark
plugs.expand_more They typically use diesel fuel, which ignites under
pressure.expand_more Similar to SI engines, they often use a four-
stroke cycle.

External Combustion Engines: In these engines, fuel is burned in a separate chamber (often a
boiler) to create hot steam or pressurized gas.expand_more This hot fluid then travels to pistons
or turbines to perform work.expand_more Examples include:

o Steam Engine: These classic engines use heated water in a boiler to

create steam that pushes pistons, converting thermal energy to
mechanical work.
o Stirling Engine: This versatile engine uses a closed loop of gas that
expands and contracts with heat from an external source, driving
pistons to create mechanical work .

By Cycle:

 Four-Stroke Cycle: As mentioned above, this is the most common cycle for
internal combustion engines.expand_more It involves four piston strokes:
Intake (drawing in air/fuel), Compression (compressing the mixture), Power
(combustion pushing the piston), and Exhaust (expelling burnt gases)
.expand_more
 Two-Stroke Cycle: These engines complete all the processes (intake,
compression, combustion, exhaust) in two piston strokes, making
them simpler but often less efficient than four-stroke engines
 expand_more They are sometimes used in small engines like
lawnmowers or chainsaws.

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 PRINCIPLES OF OPERATION

1.SPARK IGNITION ENGINE

The operation of a spark ignition (SI) engine, commonly found in petrol (gasoline) engines, is based on
the Otto cycle. The engine works by igniting an air-fuel mixture with a spark plug, generating power
through controlled combustion. Here’s a detailed look at the principles of operation for a four-stroke SI
engine, which is the most common type:

Four-Stroke Spark Ignition Engine Operation

1. Intake Stroke

 Process: The intake valve opens, and the piston moves down from the top
dead centre (TDC) to the bottom dead center (BDC).
 Function: This movement creates a vacuum that draws an air-fuel mixture
from the carburettor or fuel injection system into the combustion chamber.

2. Compression Stroke

 Process: Both the intake and exhaust valves are closed. The piston moves up
from BDC to TDC.
 Function: The upward movement compresses the air-fuel mixture,
increasing its pressure and temperature, making it more volatile and ready
for combustion.

3. Power Stroke (Combustion Stroke)

 Process: As the piston approaches TDC, the spark plug ignites the
compressed air-fuel mixture.
 Function: The ignition causes a rapid expansion of gases, generating a high-
pressure force that pushes the piston down from TDC to BDC. This
downward motion is converted into rotational motion by the crankshaft,
providing power to the vehicle.

4. Exhaust Stroke

 Process: The exhaust valve opens, and the piston moves up from BDC to
TDC.

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  Function: The upward movement expels the burned gases from the
combustion chamber out through the exhaust valve and into the exhaust
system.

Key Components and Their Functions

 Spark Plug: Generates a spark to ignite the air-fuel mixture at the right
moment during the compression stroke.
 Piston: Moves up and down within the cylinder, driven by the expansion of
gases during combustion.
 Cylinder: Houses the piston and is where the air-fuel mixture is compressed
and ignited.
 Crankshaft: Converts the linear motion of the piston into rotational motion
to drive the vehicle’s wheels.
 Valves (Intake and Exhaust): Control the flow of the air-fuel mixture into
the cylinder and the exhaust gases out of the cylinder.
 Camshaft: Operates the valves, synchronized with the crankshaft to ensure
proper timing of the intake and exhaust strokes

3. COMPRESSION IGNITION ENGINE

A compression ignition (CI) engine, commonly known as a diesel engine, operates on the Diesel cycle.
Unlike spark ignition engines, CI engines ignite the fuel by compressing air to a high temperature.

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Here’s a detailed look at the principles of operation for a four-stroke compression ignition engine, which
is the most common type:

Four-Stroke Compression Ignition Engine Operation

1. Intake Stroke

 Process: The intake valve opens, and the piston moves down from the top
dead center (TDC) to the bottom dead center (BDC).
 Function: This movement draws fresh air into the cylinder. Unlike SI
engines, only air is drawn in, not an air-fuel mixture.

2. Compression Stroke

 Process: Both the intake and exhaust valves are closed. The piston moves up
from BDC to TDC.
 Function: The upward movement compresses the air to a very high pressure
and temperature (typically above 500°C), much higher than in an SI engine.

3. Power Stroke (Combustion Stroke)

 Process: As the piston approaches TDC at the end of the compression

stroke, fuel is injected directly into the hot, compressed air in the
combustion chamber. The high temperature of the air causes the fuel to
ignite spontaneously.
 Function: The combustion of the fuel causes a rapid expansion of gases,
generating a high-pressure force that pushes the piston down from TDC to
BDC. This downward motion is converted into rotational motion by the
crankshaft, providing power to the vehicle.

4. Exhaust Stroke

 Process: The exhaust valve opens, and the piston moves up from BDC to
TDC.
 Function: The upward movement expels the burned gases from the
combustion chamber out through the exhaust valve and into the exhaust
system.

Key Components and Their Functions

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  Fuel Injector: Directly injects fuel into the combustion chamber at high
pressure, ensuring fine atomization for efficient combustion.
 Piston: Moves up and down within the cylinder, driven by the expansion of
gases during combustion.
 Cylinder: Houses the piston and is where the air is compressed and the fuel
is ignited.
 Crankshaft: Converts the linear motion of the piston into rotational motion
to drive the vehicle’s wheels.
 Valves (Intake and Exhaust): Control the flow of air into the cylinder and
the exhaust gases out of the cylinder.
 Camshaft: Operates the valves, synchronized with the crankshaft to ensure
proper timing of the intake and exhaust strokes.
 Glow Plugs: In some engines, these are used to preheat the combustion
chamber to facilitate starting in cold conditions.

3.2.3 THE DIESEL ENGINE OF THE PORT

The diesel engine of the port and what I worked with is the CAT C15 generator .
The Caterpillar C15 diesel generator is a robust and reliable power solution used
globally in various applications. Known for its durability, efficiency, and advanced
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technology, the Cat C15 generator is designed to provide consistent power for
standby, prime, and continuous power applications. This report provides an in-
depth look at the specifications, features, and applications of the Cat C15 diesel
generator.
Specifications
Engine Model: Cat C15
Engine Specifications
- Displacement: 15.2 liters (928 cubic inches)
- Configuration: Inline 6
- Bore: 137 mm (5.4 in)
- Stroke: 171 mm (6.7 in)
- Compression Ratio: 16:1
- Aspiration: Turbocharged-Aftercooled
- Fuel System: MEUI (Mechanically Actuated Electronically Controlled Unit
Injection)
- Governor Type: Electronic (ADEM A4)
Power Ratings:
- Standby Power: Up to 500 kW (625 kVA)
- Prime Power: Up to 455 kW (569 kVA)
- Continuous Power: Typically slightly lower than prime power
Key Features
High Efficiency
The C15 engine is engineered for optimal fuel efficiency, which significantly
reduces operating costs. The advanced fuel system ensures precise fuel delivery,
maximizing performance and minimizing fuel consumption.
Durability
Built to endure harsh environments and extended usage, the C15 generator features
a robust design that ensures reliable performance over long periods. Components
are constructed from high-quality materials to withstand rigorous conditions.

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Advanced Control Systems
Equipped with the latest electronic control systems, such as the ADEM A4, the
C15 generator offers precise operation and comprehensive monitoring capabilities.
This enhances the generator's performance, reliability, and ease of use.
Low Emissions
The C15 generator meets various emission standards, making it suitable for use in
regions with strict environmental regulations. The advanced combustion
technology helps reduce emissions, ensuring compliance with environmental
guidelines.
Easy Maintenance
Designed with maintenance in mind, the C15 generator features accessible service
points and comprehensive diagnostic capabilities. This simplifies maintenance
procedures, reducing downtime and ensuring continuous operation.

Application
1 .Emergency Standby
The C15 generator is ideal for emergency standby power, providing backup
electricity during grid outages. This application is crucial for critical infrastructure
such as hospitals, data centers, and government facilities, where uninterrupted
power is essential.
2 .Prime Power.
In remote locations where grid power is unavailable or unreliable, the C15
generator serves as the primary power source. This application is common in
construction sites, mining operations, and remote industrial facilities
3. Continuous Power
For applications requiring a constant and reliable power source, such as remote oil
and gas operations or telecommunications towers, the C15 generator offers
continuous power. Its robust design and efficient performance ensure a stable
power supply.

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 3.2.4 PARTS OF THE C15 DIESEL GENERATOR

A Cat C15 generator consists of two main parts: the engine and the generator.

Engine

The engine is the heart of the generator set and is responsible for converting chemical energy from fuel
into mechanical energy. A Cat C15 engine is a 4-stroke diesel engine that uses high-pressure air to
combust fuel. Here are some of the key parts:

 Block and head: The block is the main structure, and the head houses the combustion chambers

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 Pistons, rings, and connecting rods: The pistons move inside cylinders, rings seal the chamber, and
connecting rods connect pistons to the crankshaft.

 Crankshaft: Converts reciprocating motion of pistons into rotary motion.

 Camshaft: Opens and closes valves that allow air and fuel into and out of the cylinders.

 Fuel system: Delivers fuel to the engine, including a tank, pump, and injectors

 Air intake system: Filters air and delivers it to the engine, including an air filter, turbocharger, and
intercooler.

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 Cooling system: Keeps the engine from overheating, including a radiator, water pump, and thermostat.

 Exhaust system: Removes exhaust gases, including an exhaust manifold, muffler, and catalytic
converter (if equipped).

Generator

The generator converts mechanical energy from the engine into electrical energy. It consists of a rotating
armature (inner part) and a stationary field coil (outer part). When the engine turns the armature, a
magnetic field is created that induces a current in the windings of the field coil.

 Stator: The stationary part of the generator that houses the field coil.

 Rotor: The rotating part of the generator that consists of the armature.

 Voltage regulator: Controls the output voltage of the generator.

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 AVR (Automatic Voltage Regulator): A more advanced voltage regulator that automatically adjusts
the output voltage to maintain a constant level.

Additional Components

In addition to the engine and generator, a Cat C15 generator set also includes:

 Control panel: Allows you to start/stop the generator, monitor performance, and troubleshoot.

 Battery charger: Keeps the battery charged for starting the generator.

 Fuel tank: Stores fuel for the engine.

 Radiator: Part of the cooling system that helps keep the engine cool.
 Sound enclosure: Reduces the noise level of the generator.

3.3 DIESEL ENGINE INSPECTION

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 3.3.1 WHAT IS REQUIRED IN INSPECTION
Inspecting a diesel engine, like the Caterpillar C15, involves a thorough examination of various
components to ensure optimal performance and prevent potential failures. Diesel engine
inspections typically focus on two main goals: identifying potential problems and ensuring the
engine is operating within safe parameters

3.3.2 DAILY INSPECTION

Visual Inspection:

 Leaks: Checking for leaks of oil, coolant, and fuel around the engine components like hoses, clamps,
and seals.
 Belts and hoses: Inspecting the condition of belts and hoses for cracks, wear, and proper tension.
 Fluid levels and condition: Checking engine oil, coolant, and other fluids for proper levels and signs of
contamination.
 External components: Examining the engine block, head, and other external parts for cracks or
damage.
 Water in radiator level checking

Performance Checks:

 Starting: Checking if the engine starts readily and idles smoothly.

 Exhaust: Monitoring the exhaust for excessive smoke or abnormal colour, which can indicate problems
with combustion or fuel injection.
 Gauges and warning lights: Verifying that all gauges and warning lights are functioning correctly.

3.3.3 HOURLY INSPECTION

There are a few things that are to be checked every hour on the diesel engine using the control
panel readings,some of them are as follows

Engine Parameters:

 Engine speed (RPM): This indicates how fast the engine crankshaft is rotating. A normal operating
range for a Cat C15 engine might be between 1800 and 2200 RPM. Deviations from this range could
indicate overloading or engine issues.

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 Engine coolant temperature: This is crucial for maintaining proper engine operation. The coolant
absorbs heat from the engine and carries it to the radiator for cooling. The typical operating temperature
range for a Cat C15 engine could be between 180°F (82°C) and 210°F (99°C). Overheating can cause
severe engine damage.
 Engine oil pressure: Engine oil lubricates moving parts and helps dissipate heat. A healthy oil pressure
ensures proper lubrication. The recommended oil pressure range can be found in the operator's manual,
but it typically falls between 30 psi and 60 psi. Low oil pressure could indicate a lack of oil, worn
components, or a failing oil pump.
 Battery voltage: A healthy battery is necessary for starting the engine. The voltage typically ranges
between 12.5 volts and 14.5 volts. A consistently low voltage might indicate a failing battery or
alternator problems..
 Hours of operation: This indicates the total running time accumulated by the engine, which is helpful
for scheduled maintenance intervals.

Generator Parameters:

 Output voltage (AC): This is the voltage of the electricity being generated by the alternator. It should
match the nominal voltage of your electrical system (e.g., 120V or 240V). Significant deviations from
this value could damage connected equipment.
 Output current (AC): This indicates the amount of electrical current flowing through the generator's
output. It should be within the rated capacity of the generator to avoid overloading.
 Output frequency (Hz): This is the number of cycles per second of the alternating current. In most
countries, the standard frequency is 60 Hz. Fluctuations in frequency can cause problems with sensitive
electronic equipment.
 Real power output (kW): This is the actual usable electrical power being generated by the generator.
It's calculated by multiplying the voltage and current.
 Apparent power output (kVA): This is the total volt-ampere (VA) rating of the generator, which takes
into account both real power and reactive power (power used by magnetic fields in devices like motors).
 Power factor: This is the ratio of real power to apparent power. A value closer to 1 indicates efficient
power usage.

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 Warning Lights and Status Messages:

 Warning lights: These illuminate to indicate potential issues and should be addressed promptly.
Common warnings might include high engine temperature, low oil pressure, or alternator problems.
 Status messages: These provide information about the current state of the generator, such as "running,"
"stopped," or "preheat" (engine warming up before starting).

3.3.4 TROUBLESHOOTING
HARD STARTING
This is one of the most prominent problems that was faced in operation of the CAT C15 engine.
A hard starting diesel engine can be caused by a variety of issues, but some of them are:

Battery and Electrical Issues: A dead or weak battery won't provide enough power to crank the
engine. Check the battery voltage with a voltmeter and ensure it's at least 12.5 volts when the engine is
off. If the voltage is low, jump start or recharge the battery. Consider replacing an old or faulty battery.

Fuel System Problems: Check the fuel level for an obvious solution. Air in the fuel lines, a clogged
fuel filter, or a failing fuel pump can all prevent the engine from getting the fuel it needs. You can
visually inspect the fuel lines for leaks and consult your owner's manual for recommended fuel filter
replacement intervals. However, diagnosing or repairing the fuel pump yourself can be risky, so seek
professional help if you suspect a pump issue.

Cold Weather Starting and Other Issues: In cold weather, faulty glow plugs can make starting
difficult. Check your glow plug system according to your owner's manual. Additionally, a dirty air filter
can restrict airflow and contribute to hard starting. Replace the air filter if necessary. Also, starting
fluids can be used or petrol to spray in the air filter

Less Compression: The static compression ratio for an internal or an external combustion engine is
a value that use to represents the ratio of the volume of the engine combustion chamber from its
largest capacity to its smallest capacity.

It is one of the fundamental specifications for many common combustion type engines. Now if the
engine cylinder compression is less then it cannot produce enough heat to burn the fuel. For this reason,
it can be a little bit difficult to start the engine.

This type of problem can be caused by the engine due to overtime running. Normally, the compression
test for a diesel engine is done when it is cold. Usually, compression pressure is 20-30 Bar or 290-435

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PSI. Although, the standard value is 24-27 Bar or 350-400 PSI and it should not be more than 3 Bar or
43 PSI for each cylinder to cylinder.

Less Fuel Pressure: If the fuel injector supplying less fuel or fuel injector is physically damaged or it
cannot maintain fuel passing then it will cause low fuel pressure to the engine. For this problem, you
have to check some places on the engine to find out the problem and those are,

First find out that, is there any low pressure from the fuel tank to the fuel injection pump. It should have
3 to 7 PSI pressure from the fuel injector to lift the pump.

Approximately 175 atmospheric pressure should be present in the delivery of fuel from the injection
pump to the injector.

Cranking Speed Low or Damaged Battery: For this problem, the engine will moves slowly because
the fuel injection pump cannot produce enough fuel pressure to the cylinder. During this time the
maximum speed of the piston is so low that it cannot create the temperature required for the combustion.

For this reason, the engine cannot start. Normally we use to face this type of problem in the winter
season. Sometimes this problem can happen when the battery terminal has corrosion. So all the time
battery should maintain with full charges and terminals as should check.

TROUBLE SHOOTING TABLE OF A DIESEL ENGINE

3.4 DIESEL ENGINE SERVICING

3.4.1 MEANING
Diesel engine servicing refers to the routine maintenance and inspection activities performed on
a diesel engine to ensure its optimal performance, reliability, and longevity. This includes tasks
like changing the oil and filters, checking and replacing fuel and air filters, inspecting the cooling
and exhaust systems, and performing diagnostic tests. Regular servicing helps prevent
breakdowns, improves fuel efficiency, and extends the engine's lifespan.
3.4.2 EQUIPMENT USED
1. Oil Change Tools:
- Oil filter wrench: A circular tool designed to grip and turn oil filters.

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 - Drain pan: A container used to catch old oil during an oil change.

- Funnel: A cone-shaped tool for pouring new oil into the engine without spilling.
- Oil extractor pump: A device used to remove oil from the engine.

2. Fuel System Tools:

- Fuel filter wrench: A specialized wrench for removing and installing fuel filters.
- Fuel pressure tester: A gauge used to measure the pressure in the fuel system.
- Injector cleaning kit: A set of tools and chemicals used to clean fuel injectors.

3. Air Filter Tools:

- Air filter housing wrench or screwdriver: Tools for opening the air filter housing.

- Compressed air blower: A device used to blow dust and debris from the air filter and housing.

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4. Exhaust System Tools:
- Exhaust back pressure tester: A gauge for measuring exhaust back pressure.
- O2 sensor socket set: Specialized sockets for removing and installing oxygen sensors.

5. Electrical System Tools:

- Multimeter: A device for measuring voltage, current, and resistance.
- Battery load tester: A tool to test the battery's ability to hold and deliver a charge.
- Electrical terminal cleaner: Tools for cleaning corrosion from electrical terminals.

6. Belt and Hose Tools:

- Belt tension gauge: A tool to measure the tension of engine belts.
- Hose removal pliers: Pliers designed to remove hoses without damaging them.

7. General Maintenance Tools:

- Socket and wrench sets: Various sizes of sockets and wrenches for different bolts and nuts.
- Screwdrivers and pliers: Basic hand tools for various tasks.
- Torque wrench: A wrench designed to apply a specific amount of torque to a bolt or nut.

3.4.3 PRIMING
Priming in the context of diesel engines refers to the process of removing air from the fuel
system to ensure that fuel can flow smoothly from the fuel tank to the engine. This is often
necessary after servicing the fuel system, changing the fuel filter, or if the engine has run out of
fuel. The presence of air in the fuel lines can cause starting issues or make the engine run
inefficiently.

Priming can be done manually or automatically depending on the engine design. Manual priming
typically involves using a hand pump or a priming bulb to draw fuel through the system and
expel any air. Automatic priming systems may use an electric fuel pump to achieve the same
effect.

Steps for manual priming generally include:

35
1. Locate the priming pump: This is usually near the fuel filter or fuel pump.
2. Operate the pump: Use the hand pump or priming bulb to draw fuel into the system until you
see fuel without air bubbles in the transparent section of the fuel line, or until you feel resistance
in the pump.
3. Bleed the system: Open the bleed screws (if equipped) on the fuel system to allow trapped air
to escape as you pump.
4. Start the engine: Once the air is purged, the engine should start and run smoothly.

Proper priming ensures that the fuel system is free of air pockets, allowing for efficient fuel
delivery and optimal engine performance.
3.4.4 PROCESS OF SERVICING

The process of servicing a diesel engine follows a general routine, with variations depending on the
specific engine and the service interval. Here's a breakdown of the common steps:

Preparation:

Safety First: Ensure the engine is off, cool, and the vehicle is in a safe and secure location. Wear
appropriate safety gear like glasses and gloves.

Consult the Manual: Refer to the manufacturer's service manual for specific procedures and
recommended service intervals for your engine.

Inspection and Visual Checks:

General Check-up: Look for leaks, cracks, or loose components around the engine bay. Check coolant
levels, hoses, and belts for wear or damage.

Air Filter: Inspect the air filter for clogging and replace it if dirty according to the service schedule.

Fluid Levels: Check engine oil, coolant, and other fluids for proper levels and condition. Top up or
replace fluids based on the manual's recommendations.

Service Procedures:

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Oil Change: Drain the old engine oil and replace the oil filter. Refill with fresh oil of the recommended
grade and viscosity.

Fuel Filter Change: Replace the fuel filter according to the maintenance schedule. Bleeding the fuel
system to remove air pockets might be necessary after filter replacement.

Other Filter Replacements: Depending on the service interval, other filters like the cabin air filter or
crankcase breather filter might also be replaced.

Additional Services (if applicable):

Battery Maintenance: Clean the battery terminals and check the electrolyte level (if applicable).

Belt and Hose Checks: Inspect the condition of drive belts and hoses for cracks or wear. Replace them
if necessary.

Cooling System Flush: A periodic cooling system flush may be recommended to remove built-up
deposits and ensure optimal cooling efficiency.

Diagnostics: Modern diesel engines can be connected to diagnostic tools to identify any underlying
issues or error codes.

Final Touches:

Top Up Fluids: Ensure all fluid levels are topped up to the recommended levels.

Test Drive: Take the vehicle for a short test drive to check for proper engine function, listen for
abnormal noises, and ensure there are no leaks.

Service Log: Update your vehicle's service records with the details of the completed maintenance.

3.4.5 IMPORTANCE OF SERVICING

Here are six important reasons for diesel engine servicing:

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1. Enhanced Performance and Efficiency: Regular servicing ensures that all engine components
are working optimally, leading to better performance and fuel efficiency. Clean filters, properly
adjusted valves, and well-maintained injectors help the engine run smoothly and efficiently.

2. Prolonged Engine Life: Routine maintenance helps prevent premature wear and tear of engine
components. By addressing minor issues before they become major problems, servicing can
significantly extend the lifespan of the engine.

3. Reduced Risk of Breakdowns: Regular checks and servicing help identify and fix potential
problems early, reducing the likelihood of unexpected breakdowns. This increases reliability and
reduces downtime, especially important for commercial vehicles and machinery.

4. Cost Savings: Preventive maintenance is generally more cost-effective than emergency

repairs. Regular servicing can help avoid costly repairs by catching issues early and maintaining
the engine’s efficiency, which can also save on fuel costs.

5. Compliance with Emission Regulations: Proper maintenance ensures that the diesel engine
operates within the required emission standards. Regularly servicing components like the
exhaust system and diesel particulate filter (DPF) helps in reducing harmful emissions.

6. Safety: A well-maintained engine is less likely to suffer from critical failures that could lead to
dangerous situations, such as engine fires or sudden breakdowns in hazardous locations.

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 CHAPTER 4

INSTALLATIONS IN PORT

4.1 INSTALLATION OF SOLAR LIGHT

4.1.1 MEANING
Solar light refers to a type of lighting that harnesses energy from the sun to produce light. It typically
consists of several key components, including solar panels, batteries, LED lights, and a control system.
Here’s a breakdown of how solar lights work and their components:

1. Solar Panels: These are the key components that convert sunlight into electrical energy. Solar panels,
also known as photovoltaic cells, capture sunlight and convert it into direct current (DC) electricity.

2. Battery: The electricity generated by the solar panels is stored in a battery. This allows the solar light
to function even when there is no sunlight, such as at night or during cloudy days.

3. LED Lights: Light-emitting diodes (LEDs) are used in solar lights because they are energy-efficient
and have a long lifespan. LEDs convert the stored electrical energy into light.

4. Control System: This includes a controller that manages the charging of the battery and the operation
of the LED lights. The control system often includes sensors that automatically turn the lights on at dusk
and off at dawn.

Applications of Solar Lights:

- Outdoor Lighting: Solar lights are commonly used for garden lights, pathway lights, street lights, and
security lights.
- Emergency Lighting: They can be used as a backup source of light during power outages.
- Remote Areas: Ideal for providing lighting in areas without access to the electrical grid.

Advantages of Solar Lights:

- Environmentally Friendly: They use renewable energy from the sun, reducing the carbon footprint.

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- Cost-Effective: After the initial installation cost, solar lights have minimal operational costs as they do
not rely on electricity from the grid.
- Low Maintenance: Solar lights generally require less maintenance compared to traditional lighting
systems.
- Easy Installation: They do not require wiring to the electrical grid, making installation simpler and
more flexible.

In summary, solar lights are an efficient, sustainable, and versatile lighting solution that utilizes solar
energy to provide illumination.

4.1.2 PROCEDURE OF INSTALLATION

Here's a concise outline of how to mount a 200W solar street light on a road using a crane:

1. Site Preparation:
- Choose a sunny, level location and clear any obstacles.

2. Foundation Installation:
- Dig a hole, install anchor bolts, and pour concrete for the foundation.

3. Assemble Components:
- Assemble the solar panel, LED light, battery, and control system.

4. Attach Pole and Fixture:

- Lay the pole down and attach the light fixture securely.

5. Crane Setup:
- Position the crane nearby and extend its boom.

5. Lift and Install Pole:

- Attach lifting straps to the pole, lift it into place, align with anchor bolts, and secure.

40
7.Connect Electrical Components:
- Wire the solar panel to the battery and control system.

8. Test and Verify:

- Test the functionality of the solar street light system.

9. Clean-up:
- Remove any debris and ensure the area is clean and safe.

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 CHAPTER FIVE

5.1 Challenges Encountered During Industrial Training

Here are some challenges I faced during my industrial attachment in the Nigerian Ports
Authority engineering department:

1. Limited Practical Exposure: I found it challenging to gain hands-on experience with the
sophisticated industrial equipment and processes used in the engineering department, which
affected my learning curve.

2. Safety Regulations: Adhering to stringent safety protocols and regulations in such a dynamic
industrial setting was overwhelming at times, requiring constant attention to detail and adherence
to safety guidelines.

3. Communication Barriers: Language differences or technical terminology used in the

workplace posed challenges for me in effectively communicating with industry professionals,
impacting my task comprehension and performance.

4. Equipment Availability: Limited access to state-of-the-art equipment and tools necessary for
learning and practical application restricted my ability to fully engage in assigned tasks and
projects.

5. Workload Management: Balancing my academic commitments with the demands of a full-

time attachment was demanding, especially when tasks required extended hours or strict
deadlines.

6. Adapting to Organizational Culture: Adjusting to the organizational structure, workplace

hierarchies, and professional norms within the Nigerian Ports Authority required time and effort
to navigate effectively.

7. Technical Challenges: Dealing with technical issues or equipment breakdowns during tasks
tested my problem-solving abilities and resilience, influencing my overall learning experience.

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8. Limited Mentorship: Due to staffing constraints and workload, I encountered challenges in
receiving consistent mentorship and guidance from experienced professionals, impacting my
professional development.

5.2 Conclusion

My industrial training at the Nigerian Ports Authority engineering department was an invaluable
experience that provided me with extensive practical knowledge and exposure to real-world
engineering practices. Throughout the attachment, I encountered several challenges, including
limited practical exposure, stringent safety regulations, communication barriers, equipment
availability issues, and workload management. By actively seeking guidance, improving my
communication skills, and prioritizing safety and time management, I was able to turn these
challenges into significant learning opportunities that enhanced my professional development.

The training allowed me to apply theoretical knowledge from my academic studies to practical
situations, deepening my understanding of engineering principles and processes. Working
alongside experienced professionals, I gained insights into the complexities of maintaining and
operating port infrastructure and machinery. This hands-on experience not only improved my
technical skills but also helped me develop crucial problem-solving abilities, adaptability, and
resilience. Overall, my time at the Nigerian Ports Authority engineering department was a
transformative period that effectively bridged the gap between academic learning and
professional practice, preparing me well for future challenges in the engineering field.

5.3 Recommendations

Certainly! Here are solutions to five of the challenges faced during industrial attachment in the
Nigerian Ports Authority engineering department:

1. Take initiative to ask for more hands-on tasks and projects. Engage proactively with
supervisors to shadow experienced technicians and operators. Seek opportunities to participate in
training sessions or workshops that offer practical experience.

2. Prioritize safety at all times. Familiarize yourself with safety protocols and guidelines early
on. Always wear personal protective equipment (PPE) and participate actively in safety training
programs. Seek guidance from experienced colleagues when unsure about safety procedures.

43
3.Improve communication skills by actively listening and asking clarifying questions. Take the
initiative to learn industry-specific terminology and communicate clearly and effectively. Build
rapport with colleagues to create an open dialogue and seek feedback on your communication.

4. Make the most of available resources by understanding the capabilities and limitations of the
equipment provided. Take initiative to propose improvements or upgrades if feasible. Seek
guidance from supervisors on alternative methods or tools to accomplish tasks effectively.

5. Prioritize tasks based on deadlines and importance. Break down larger tasks into smaller,
manageable parts and set realistic goals. Communicate with supervisors about workload
concerns and seek guidance on prioritization. Develop time management skills to optimize
productivity and efficiency.

REFERENCES

1. Diesel Engine References:

- Heywood, J. B. (1988). Internal Combustion Engine Fundamentals. McGraw-Hill Education.
- Stone, R. (1999). Introduction to Internal Combustion Engines. Palgrave Macmillan.
- Bosch, R. (2000). Diesel-Engine Management. Robert Bosch GmbH.

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2. Solar Installation References:
- Green, M. A. (2004). Solar Cells: Operating Principles, Technology, and System Applications. The
University of New South Wales.
- Messenger, R. A., & Ventre, J. (2010). Photovoltaic Systems Engineering. CRC Press.
- Wenham, S. R., Green, M. A., & Watt, M. E. (2013). Applied Photovoltaics. Routledge.

3. Operating Principles of Other Engines:

- Pulkrabek, W. W. (2003). Engineering Fundamentals of the Internal Combustion Engine. Pearson
Education.
- Ferguson, C. R., & Kirkpatrick, A. T. (2001). Internal Combustion Engines: Applied
Thermosciences. John Wiley & Sons.
- Blair, G. P. (1999). Design and Simulation of Four-Stroke Engines. SAE International.

4. General Engineering and Technical References:

- Hibbeler, R. C. (2017). Engineering Mechanics: Dynamics. Pearson.
- Norton, R. L. (2011). Machine Design: An Integrated Approach. Pearson.
- Pritchard, P. J., & Leylegian, J. C. (2016). Fox and McDonald's Introduction to Fluid Mechanics.
Wiley.

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