A Technical Report on

Student Industrial Work Experience Scheme (SIWES)

At

KENOC NIGERIA LIMITED

278 Aba Expressway, Rumukwurushi Junction,
Port Harcourt, Rivers State.

By

UDOUKPA, VICTOR SYLVANUS

AK16/ENG/MAE/056
Marine Engineering

SUBMITTED TO:

Mr. Anietie Udo

SIWES COORDINATOR
AKWA IBOM STATE UNIVERSITY, IKOT AKPADEN.

IN PARTIAL FULFILMENT FOR THE AWARD OF BACHELOR OF ENGINEERING

(B.ENG) DEGREE IN MARINE ENGINEERING

June 2021
 A Technical Report on
Student Industrial Work Experience Scheme (SIWES)

At

KENOC NIGERIA LIMITED

278 Aba Expressway, Rumukwurushi Junction,
Port Harcourt, Rivers State.

By

UDOUKPA, VICTOR SYLVANUS

AK16/ENG/MAE/056
Marine Engineering

SUBMITTED TO:

Mr. Anietie Udo

SIWES CORDINATOR
AKWA IBOM STATE UNIVERSITY, IKOT AKPADEN.

IN PARTIAL FULFILMENT FOR THE AWARD OF BACHELOR OF ENGINEERING

(B.ENG) DEGREE IN MARINE ENGINEERING

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 DEDICATION

This work is dedicated to the glory of Almighty God who gave me the grace to serve and complete
my Industrial training successfully, may His name glory. Amen.

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 ACKNOWLEDGEMENT

With profound gratitude to the Almighty God for his love and mercies, which have enabled me to
complete my Industrial Training for six (6) months.

I am highly indebted to the management and apprentices at Kenoc Nigeria Limited for the
opportunity given to me to acquire this knowledge. I specifically thank the Director, Mr. Kenneth
Okafor Igwe for the patience he usually takes to explain things in their simplest form for my
understanding.

I also use this opportunity to appreciate my family for their supports materially and in prayers
throughout the program. I am extremely grateful to the school administration for allowing me to
blend my theoretical knowledge with practical and expose me to the work environment. I pray
many folds of rewards to them for their sacrifice in ensuring that I complete my Industrial Training
with excellence.

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 ABSTRACT

Industrial Training is an important phase of student’s life. A well-planned, properly executed, and
evaluated industrial training helps a lot in developing a professional attitude toward any future
endeavour. Chapter one of this report presents the meaning, aim, and the respective organized
bodies involved in the successful implementation of the SIWES program. Chapter two present the
summarized corporate information above Kenoc Nigeria Limited as well as its organizational
chart. Chapter three is detailed information about the projects executed and my contributions to
the success of the projects. It also summarized my experience gained while contributing to the
success of these projects. I gained adequate experience in the area of mechanical workshop
management and planning, different types of diesel engines, manufacturer and specifications
accompanying each of these diesel engines. Their maintenance tips as well as their different
components.

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 TABLE OF CONTENTS

COVER PAGE .............................................................................................................................. 1

TITLE PAGE……………………………………………………………………………………...2

DEDICATION……………………………………………………………………………………3

ACKNOWLEDGEMENT………………………………………………………………………...4

ABSTRACT……………………………………………………………………………………….5

TABLE OF CONTENTS………………………………………………………………………….6

CHAPTER ONE ............................................................................................................................. 8

INTRODUCTION ........................................................................................................................ 8

1.1 STUDENT INDUSTRIAL WORK EXPERIENCE SCHEME (SIWES)

BACKGROUND ......................................................................................................................... 8

1.2 OBJECTIVES OF SIWES ............................................................................................... 8

1.3 BODIES INVOLVED IN THE MANAGEMENT OF SIWES ....................................... 9

CHAPTER TWO ........................................................................................................................ 10

BACKGROUND OF COMPANY/ORGANIZATION ........................................................... 10

2.1 INTRODUCTION .......................................................................................................... 10

2.2 HISTORY....................................................................................................................... 10

2.3 ORGANOGRAM ........................................................................................................... 11

CHAPTER THREE .................................................................................................................... 12

PROJECT EXECUTED, CONTRIBUTIONS AND EXPERIENCE GAINED ..............Error!

Bookmark not defined.

3.1 INTRODUCTION ...........................................................Error! Bookmark not defined.

3.2 EXPERIENCE…………………………………………………………………………13

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CHAPTER FOUR....................................................................................................................... 39

5.3 RECOMMENDATION ...................................................................................................... 39

5.4 CONCLUSION ................................................................................................................... 39

REFERENCES............................................................................................................................ 40

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 CHAPTER ONE
INTRODUCTION

1.1 STUDENT INDUSTRIAL WORK EXPERIENCE SCHEME (SIWES) BACKGROUND

The Government’s decree No. 47 of 8th October 1971 as amended in 1990 Highlighted the capacity
building of human resources in the industry, commerce, and government through training and
retraining of workers to effectively provide the needed high-quality goods and services in a
dynamic economy as ours (Jemerigbo, 2003). This decree led to the establishment of the Industrial
Training Fund (ITF) in 1973/1974
The growing concern among our industrialists that graduates of our institution of higher learning
lack adequate practical background studies preparatory for employment in industries led to the
formation of the Students Industrial Work Experience Scheme (SIWES) by ITF in 1993/1994
(Information and Guideline for SIWES, 2002). ITF has one of its key functions; to work as a
cooperative entity with industry and commerce where students in institutions of higher learning
can undertake mid-career work experience attachment in industries that are compatible with the
area of study (Okorie 2002).
The students Industrial Work Experience Scheme (SIWES) is a skill training program designed to
expose and prepare students of Agriculture, Engineering, Environmental Science, Medical
Sciences, Pure and Applied Sciences for the industrial work situation which they are likely to meet
after graduation and also to bridge the gap existing between there theoretical knowledge and
practice. Duration of SIWES is four (4) months in Polytechnics at the end of NDI, four (4) months
in College of Education at the end of NCE II, and six (6) months in the universities at the end of
300, 400, or 500 levels depending on the discipline (Information and Guideline for SIWES, 2002).

1.2 OBJECTIVES OF SIWES

The objective of SIWES among others includes:

i. prepare students for the industrial work situation which they are likely to meet after
graduation,
ii. provide an avenue for students in institutions of higher learning to acquire industrial
skills and experience in their approved course of study,

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 iii. expose students to work methods and techniques in handling equipment and machinery
not available in their institutions
iv. provide students with an opportunity to apply their knowledge in real work situation
thereby bridging the gap between theories and practices, and vi
v. enlist and strengthen employers’ involvement in the entire educational process and
prepare students for employment in industry and commerce (Information and guideline
for SIWES 2002)

1.3 BODIES INVOLVED IN THE MANAGEMENT OF SIWES

 Federal Government through the Federal Ministry of Industry, Trade, and Investment.
 Industrial Training Fund (ITF), SIWES division.
 Supervisory/Regulatory Agencies (NUC, NBTE, NCCE).
 Industry/Employers.
 Tertiary Institutions (Universities, Polytechnics, Colleges of Education), and
 Students

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 CHAPTER TWO
BACKGROUND OF COMPANY/ORGANIZATION

2.1 INTRODUCTION
Kenoc Nigeria Limited is one of the leading heavy-duty diesel engine workshops in Rivers
State and one of the most reputable in the entire South-South of Nigeria with Reg no. RC
350385

Kenoc Nigeria Limited is a duly registered and certified brand in the automobile industry,
whose operations in Nigeria have spanned over one decade. The organization has trained over
50 mechanics and extension empowering them economically. Kenoc Nigeria Limited are up to
date with the latest trends and technologies in heavy-duty diesel engines and also dedication to
solution and innovation which gives an outstanding edge over their competitors.

Kenoc Nigeria Limited have four departments, namely;

 Maintenance and repairs department

 General cleaning services

2.2 HISTORY
Name of the company

The name of the company was derived from part of the CEO’s name; Mr. Kenneth Okafor
Igwe. The name of the organization is KENOC NIGERIA LIMITED.

Address of the company

Kenoc Nigeria Limited is located in Rives State at 278 Aba Expressway, Rumukwurushi
Junction, Port Harcourt, Rivers State.

Commencement date

Kenoc Nigeria Limited started operation on 1st May 1999 with an address at the same address
above.

Activities of the company

Kenoc Nigeria Limited specialize in;

 The company is generally into the maintenance and repairs of marine engines.

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2.3 ORGANISATIONAL CHART OF KENOC NIGERIA LIMITED

CEO

Manager

Secretary Workers Cashier

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 CHAPTER THREE
PROJECT EXECUTED, CONTRIBUTIONS AND EXPERIENCE GAINED

3.1 INTRODUCTION
The primary aim of embarking on this Industrial training is to gather experience that will enable
me to bridge the gap between my theoretical and practical knowledge.

Outline of some experience gained:

1. General diesel engine overhauling techniques
2. Servicing of rocker arm assembly
3. Valve lash setting
4. Servicing of turbocharger
5. Maintenance of heat exchangers
6. Valve grinding and servicing of cylinder head
7. Installation of new cylinder liners
8. Installation of new Kickstarter.

4.2 EXPERIENCES

i) Identification of engine components

During my first one month of Industrial Training I was exposed to some of the components
that makes up a complete engine. I had the experience of differentiating between an original
or fake components by physical inspection and their cost.
Names of components
 Engine block
 Cylinder head assembly
 Rocker arm assembly: rocker shaft, holding block, rocker lever, springs, shims and
washer
 Piston assembly: connecting-rod and cap, piston pin, snap rings and piston
 Cylinder liners
 Crankshaft
 Camshaft
 Gears
 Oil pump and sump
 Valve cover
 Breather
 Turbocharger
 Exhaust manifold

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ii) General diesel engine overhauling techniques

Main specification of the Man Marine engine

Engine model: MM6-250L

No. of cylinder: V12

No. of stroke: 4 strokes

RPM: 1750

Displacement: 772 in3

Combustion Chamber Type: Direct Injection

Condition of the Engine:

Misfiring of the engine as a result of excessive injection of fuel into the combustion chamber
during combustion. This imposes excessive thermal stress on the engine component resulting
into broken valves, piston, cylinder head, cylinder lines (sleeves), main and connecting-rod
bearing.

Overhauling of engine

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Procedures for dismantling and reassembling of the Man Marine engine

 The engine was dismantled from the truck and complete disassembling of the engine
components.
 After taking down the engine piece by piece, the entire components were washed using
diesel, petrol and hot water mixed with detergent for easy remove of the oil and carbon
deposits.
 The damaged components (valve, piston, main and connecting rod bearings, dry cylinder
liners (sleeves), cylinder head and cylinder head gasket).
 The cylinder head was decarbonized and washed properly; and thereafter grinding of the
valves using grinding paste to reface the valve seat.
 Decarbonizing and washing of the engine block to remove oil deposit and unblock all oil
passages in the engine block.
Reassembling

 The dry cylinder liners (sleeves) were installed into the engine block cylinder bore using
flat wood across the bore and hitting carefully with a soft hammer to drive the sleeves into
the block bore.
 The main bearings were installed on the engine block and on the main bearing caps
 Preparation of the pistons:
- The piston ring contains four (4) rings in a set according the number of groove on the
piston. There (3) compression rings and an oil ring with expander.
- The rings were carefully installed on the grooves noting the right facing and positions.
 The connecting-rod were fitted back into the piston with the key end of the connecting-rod
facing the bigger side of the piston crown.
 The bearings were then installed respectively on both the connecting-rods and the caps.
 Installation of the crankshaft: during the installation of the crankshaft, it was carefully
install so that the crankshaft main bearing journals seats properly on the engine block bore
and then the thrust washer was inserted at the side of the middle double block main bearing
journal.
 The engine was timed using the timing marks located on the gear. The camshaft was
installed and timed to the crankshaft with the caret “^” mark on the gear teeth of the
camshaft engaging in the double caret “^ ^” marks on the gear teeth of the crankshaft.
This initial timing is very important as the opening and closing of the valve and as well as
the accurate four (4) stroke cycle depends on it.
 After installation and proper timing of the crankshaft to the camshaft gear, the crankshaft
was rotated to ensure that its rotates freely.
 The crankshaft was tightened to the engine block with the main bearing cap using 25mm
bolt. For each cap installed and tightened, the crankshaft was rotated to still ensure it rotates
freely in the engine block bore. The installation and tightening of the main bearing cap was
done in the sequence of 1 – 7 – 6 – 2 – 3 – 5 – 4.
 The timing gear cover was then installed on the engine to protect the gears.
 The pistons were now installed into the cylinder liners with the bigger end of the
connecting-rod facing the camshaft direction while the rings compressor was used to guild
the rings together the piston in the cylinder liners(sleeves). Care was taken so that the piston
rings will not be damaged during the installation.
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 The connecting-rod caps were used to tightened the connecting-rods to the crankshaft
connecting-rod journals using 17mm bolt. The engine crankshaft was rotated to ensure free
and seamless rotation.
 The flywheel housing was installed to the engine block using 19mm bolts.
 The air compressor and the engine block side cover were installed and tightened with 14mm
bolt to their correct torques.
 The flywheel was then installed into the flywheel housing (banjo) and tightened with 19mm
bolts.
 The clutch plate and clutches were installed as well.
 The cylinder head gasket was installed on the engine before installing the cylinder head
along with it accessories (exhaust manifold, turbocharger, etc).
 The injection pump was installed to the injection pump drive gear after been timed to the
crankshaft.
 The oil filter base and the water pump were installed properly at their respective locations.
 The push rods were slide down into the engine to sit on the valve lifter (tappets) using a
clean engine oil through the openings on the cylinder and the engine block and thereafter
the rocker arm assembly was installed on the cylinder head and ensuring that the push-rod
contact end rest properly on the push-rod tips.
 Setting of valve lash using feeler gauge of 0.40mm thick, 16mm spanner and a flat screw
driver. This was done to ensure that the valve stem tip and the rocker lever tip have their
proper clearance to avoid damage to the valve during operation.
 After all other components were installed on the engine, the engine was test run. 38 litres
of SAE 40 engine oil was poured into the engine and a temporary diesel fuel source was
provided.
 The engine was successfully started and later mounted on the truck along with the cooling
systems.

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 SUMMARY OF ENGINES OVERHAULLED

SN MAN. MODEL NO. OF TYPE OF BORE STROKE CHARGE PROBLEMS DEVELOPED

CYL COMBBUSTION (mm) MODE
LENGTH
CHAMBER
(mm)

1 Man Marine for main MM6- V12 Direct Injection 187 155 Turbo- Excessive exhaust smoke due to bad
engine 250L (DI) charged fuel injector nozzle calibration

2 Cummins engine for 4 – inline Direct Injection 123 153 Turbo – Malfunctioning of the engine
generating set mover (DI) charged components

3 Man Marine for main MM6- V12 Direct Injection 187 155 Turbo- Excessive consumption of engine oil
engine 250L (DI) charged

4 Cummins engine for 4 – inline Direct Injection 123 153 Turbo – Misfiring of the engine due to improper
generating set mover (DI) charged calibration of the fuel injector pump

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iii) Valve lash adjustment (Valve settings)

Valve lash is measured between the rocker arm and the valve stem for the exhaust valve. All
of the clearance measurements and the adjustments must be made with the engine stopped. The
valves must be fully closed. The valve lash adjustment is the procedure for setting the clearance
between the rocker lever and the tip of the valve stem to the required standard clearance.

Setting of valve clearance using feeler gauge of 0.35mm thick for inlet valve
and 0.64mm thick for exhaust valve

Procedures:

 Lightly tap the rocker arm at the top of the adjustment screw with a soft mallet. This will
ensure that the lifter roller seats against the camshaft's base circle
 Loosen the adjustment locknut and place the appropriate feeler gauge between the rocker
arm and the valve bridge. Then, turn the adjustment screw in a clockwise direction. Slide
the feeler gauge between the rocker arm and the valve bridge. Continue turning the
adjustment screw until a slight drag is felt on the feeler gauge. Remove the feeler gauge.
 Tighten the adjustment locknut. Do not allow the adjustment screw to turn while you are
tightening the adjustment locknut. Recheck the valve lash after tightening the adjustment
locknut. Remove the timing bolt and turn the flywheel by 360 degrees in the direction of
engine rotation. This will put the No. 6 piston at the top center position on the compression
stroke. Install the timing bolt in the flywheel.

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iv) Valve grinding and servicing of cylinder head

Valve lapping is the process of grinding or lapping the valve onto its seat with the aid of a fine
grinding paste.
The procedure to lap a valve is as follows:
 The valves were first removed from the cylinder head and washed to remove some of the
carbon deposits from it.
 A thin layer of grinding paste was applied around the valve face.
 The valve stems were lubricated and placed into its appropriate guide. Care was taken to
ensure that the valves were returned into the exact guide it was removed from.
 The valves were rotated approximately for about five (5) minutes until a narrow lapping
mark appears on the valve face.
 The grinding paste was cleaned off of the valve and the valve seat using a soft cloth.
 Each of the valve seating face and valve stems were lubricated before fitting back into the
cylinder head.

Washing of Cylinder head and Valve grinding

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v) Servicing and Repair of a Turbocharger

Problem:

 Worn out turbine ring seal which results in the leakage of oil through the turbine wheel.
 The buildup of carbon deposits on the turbine wheel and the oil tunnels in the center
housing causing insufficient lubricating oil.

Solution:

 A punched mark was made on the turbine and compressor housing and on the center
housing to ensure proper positioning of the housing when assembling.
 The turbocharger was disassembled by removing the clamp and carefully removing the
turbine and compressor housing first and then using a 17mm spanner to loosen the
compressor wheel holding bolt.
 The components of the turbocharger were disassembled carefully and washed using
diesel fuel to remove carbon and oil deposits.
 The faulty components were isolated for replacement and the center housing was
carefully scrapped to remove the oil deposits.
 The washed components were sun-dried while waiting for the replacement of the worn-
out ring seals.
 A clean engine oil, lint-free rag, pin plier, 17mm combination spanner, and a light
hammer were the tools used for the assembling.
 The assembling started with the installation of the snap rings and the journal bearings
in the center housing and then followed by the installation of the turbine forged with
the drive shaft.
 The thrust collar, thrust bearing, oil deflector, thrust plate along with the O-ring seal,
and then the compressor wheel.
 The shaft end was tightened with the 17mm bolt to secure the compressor wheel.
 The turbine and compressor housing was then installed at their respective positions and
in the direction as marked before disassembling.

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 CHAPTER FOUR
CONCLUSION RECOMMENDATION AND CHALLENGES

CONCLUSION

This report gives a brief account of my experience with Kenoc Nigeria Limited at 278 Aba
Expressway, Rumukwurushi Junction, Port Harcourt, Rivers State. The report covers my
experience in maintenance, installation, proper tools handling techniques, repairs of diesel
engines/generators, setting of valves and basic maintenance. At the end of the industrial
training, I was able to carry out a complete overhauling of Man Marine V12 Engine and
Cummins 4-cylinder diesel engines with little supervision. Servicing of turbocharger with oil
leakage problem. I learnt the skill of troubleshooting diesel engine by physical inspection and
using the sound developed by the engine

RECOMMENDATION
Considering the difficulty, I went through during my industrial training, I will recommend a
review of this programme to be more of practical and purpose driven. The departmental
managements should assist the students by securing a place of industrial training attachment
for the students. This will help the student participate fully in this program in time instead of
spending time searching for a place of attachment.

CHALLENGES

 Long distance of place of industrial attachment.

 Restricted from some areas in the workshop.

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