A REPORT OF POST GRADUATE

PRACTICAL EXPERIENCE IN INDUSTRIAL/PRODUCTION

ENGINEERING

PRESENTED

BY

UGODU KINGSLEY OBUM

(B. ENG. INDUSTRIAL PRODUCTRION ENGINEERING)

(M.ENG. INDUSTRIAL/PRODUCTION ENGINEERING IN VIEW)

IN

PARTIAL FULFILLMENT OF THE REQUIREMENT FOR

REGISTRATION AS AN ENGINEER

TO THE

COUNCIL FOR THE REGULATION OF ENGINEERING IN NIGERIA

(COREN)

JANUARY, 2019.

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CERTIFICATION

This is to certify that the report on the post graduate practical work experience in

Industrial/Production Engineering presented by Ugodu, Kingsley Obum to the

Council for the Regulation of Engineering in Nigeria (COREN) for registration as

an Engineer is original and a true reflection of experience gathered.

Name: Engr.………………………………………..

COREN Registration Number: …………….

Signature and date……………………………..

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DEDICATION

This work is dedicated above all, to the Almighty God for His mercies, guidance,

protection and enablement to be called, an Engineer.

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ACKNOWLEDGEMENT

Special thanks goes to Almighty God for his guidance and for the gift of Life. Also

to my parents and other family members, for their moral and financial support all

through my undergraduate and current postgraduate studies.

I wish to appreciate all academic and non-academic staffs of Industrial/Production

Engineering Department of Nnamdi Azikiwe University, Awka, for their

contributions as it concerns my academic pursuits and also my mentors in the

Telecom industry who moulded me.

I wish to also acknowledge the support and guidance received from Engr. Okolie,

Paul C. O. of the Department of Mechanical Engineering Nnamdi Azikiwe

University,Awka, other friends and colleagues alike.

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ABSTRACT

This technical report is a compilation of postgraduate experience garnered from

2014 to date not excluding the experience added during my Industrial Training

program. It provides a brief summary of my educational background, Industrial

Training exercise and National Youth Service Corps (NYSC) experiences while

section two through section four cover Post NYSC work experiences, including

various challenges encountered and solutions proffered during this period. It also

covers a brief on Hybrid energy solutions and overhauling of a 20kva generator

set.

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TABLE OF CONTENTS

Title
Page…………………………………………………………………………………
………………………….…..1

Certification
……………………………………………………………………………….............
.......……….…2

Dedication……………………………………………………………………………
……………………………….…3

Acknowledgement…………………………………………………………………
………………………………4

Abstract………………………………………………………………………………
…………………………………...5

Table of contents
………………………………………………………………………………….
………………..6

1.0Brief Biography …………………………………………………………..

……………………………………..7

1.1 Industrial Training at Scientific Equipment Development Institute (SEDI-E)

Enugu………………………………………………………………………………
………………………………………...7

1.2 National Youth Service Corps (NYSC) Experience in Government Secondary

school Isiokpo, Rivers state….
………………………………………………………….……………………....8

2.0 Post National Youth Service Corps (NYSC) Experience

………………………….…..9

2.1 Experiences at MP Infrastructure Limited

…………………………………………………………9

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2.2 Experiences at Infravision
limited………………………………………………………………….…..10

2.3 Experiences at Electronics Development Institute

………………………………………….11

3.0 Hybrid Energy solution……………….

…………………………………………….………………………..12

4.0 Overhauling of a 20kva Diesel Generator set…….

………………………………………….20

4.1 Bill of Engineering measurement and

evaluation………………………………………….22

5.0 Conclusion and Recommendation…………………….

…………………………………..…………23

1.0 BRIEF BIOGRAPHY

My name is Ugodu Kingsley Obum. I was born on the 28th day of July, 1989.

My hometown is Affa in Udi Local Government Area of Enugu State.

I attended the following institutions;

 Nnamdi Azikiwe University, Awka, Anambra State 2007-2012

 Sacred Heart Seminary, Nsude, Enugu, Enugu State. 2000-2006

 Immaculate Heart Primary School Ogui Enugu, Enugu State. 1994-2000

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 I obtained the following qualifications.

 Bachelor of Engineering in Industrial and Production Engineering (B.ENG)

 Senior School Certificate Examination (SSCE/NECO)

 First School Leaving Certificate (FSLC)

1.1 INDUSTRIAL TRAINING (IT) AT SCIENTIFIC EQUIPMENT

DEVELOPMENT INSTITUTE (SEDI-E), ENUGU. (APRIL 2011 –
SEPTEMBER 2011)

During this compulsory six (6) months Industrial Training exercise, I harnessed a lot
knowledge and Technical know-how working in four major sections of the institute;

 Machine Building workshop

 Machine shop workshop
 Mechanical Maintenance workshop
 Advanced Engineering section

Among my duties at these sections include:

MACHINE BUILDING WORKSHOP:

Worked as a co-design analyst in analyzing and fabrication of equipment and machines.
Also practiced Welding, folding and various Bench work operations.

MACHINE SHOP WORKSHOP:

Worked as an Operator in the use of Lathe, Engraving, Milling and Drilling machine in
performing set objectives to achieve a desired result.

MECHANICAL MAINTENANCE:

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Helped in the Overhaul maintenance schedule of the mechanical machines used in the
Various sections in the institute. Also in Preparing Maintenance schedules and Repairs
when necessary.

ADVANCE ENGINEERING:
Here, I was groomed in the use of AutoCAD and SOLIDWORKS application to design,
draw, create and analyze engineering drawings.

1.2 NATIONAL YOUTH SERVICE CORPS (NYSC) EXPERIENCE IN

GOVERNMENT SECONDARY SCHOOL ISIOKPO, RIVERS STATE. (2013 -
2014)

During the one year mandatory program, I tutored senior secondary students in Physics;
practical inclusive. Where I prepare them for the senior secondary certificate
examination, and also served as their form master.
My services to the people of Isiokpo and Ikwere Local Government Area didn’t end in
the classroom as I also served as the Cadet-in-chief, Federal Road safety Corp Club,
Isiokpo command. The exposure and position involved a lot of sensitization programs on
High way codes, Traffic rules as well as Safety measures. The target audience were the
motorists, cyclists, students, market men and women, and all road users.

2.0 POST NYSC WORK EXPERIENCE

2.1 MP INFRASTRUCTURE LTD

Plot 23, Block 68 Bisola Durosinmi Etti Drive, Lekki Phase 1, Lagos State.
PERIOD: October 2015 –March, 2017
Industry: Telecommunication (Passive)
Position: Field Support Engineer (FSE)

DUTIES PERFORMED:

 Ensure total compliance to quality, health and safety standards.

 Ensure proper management of power equipment delivered to sites.

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  Evaluate sub-contractors work on ongoing basis.
 Ensure proper monitoring of assets on sites and report promptly.
 Responsible for installation and maintenance of power and sync equipment.
 Ensure to maintain an average response time of less than one hour and an average
resolution time of less than two hours.
 Ensure that daily, weekly and monthly reports from myself and team members are
accurate and on time.
 Site housekeeping and Janitorial of sites must be with highest possible quality.
 Ensure that your team members are given objectives for each review period and
the performance review is conducted in accordance with HR requirements and
timelines.
 Ensure regular feedback and reporting to the Project Manager and the Supervisor.
 Ability to apply technical solutions to real time project problems.

Challenge(s) Encountered and Solution(s) Proffered

The field team is always the first point of contact in the escalation matrix for any site
failure. Failures can occur at any time of the day or night; of course it’s a major challenge
for night escalations especially with cases of high risk areas and theft prone areas within
the region.

To ensure safety and also maintain required uptime of 99.5% minimum, Remote
monitoring systems (RMS) is the first solution to monitor and detect failures and alarms
on power equipment. With proper emphasis and project plan, this was installed and as a
contributing factor, PPM (periodic preventive maintenance) and spot checks were a must
to help in proper servicing of power equipment; so as to increase its life span and avoid
breakdowns.

2.2 INFRAVISION LTD.

Plot 23, Block 68 Bisola Durosinmi Etti Drive, Lekki Phase 1, Lagos State.
PERIOD: August 2017 – April, 2018
Industry: Telecommunication (Passive)
Position: Regional Supervisor Maintenance

DUTIES PERFORMED:
 Supervise the activities of passive maintenance field staffs and ensure they
maintain an average response time of less than an hour
 Breakdown analysis report collation and preventive maintenance schedule
planning

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  Troubleshooting and Remedy proffered solution on Hybrid power solutions on cell
sites.
 Coordinate the maintenance of all diesel generators and other passive related
equipments, Diesel delivery and Janitorial under the team coverage.
 Manage issues and risks on site and ensure field staff and subcontractors comply
to standard.
 Ensuring High network availability through meeting clients SLAs (service-level-
agreement)
 Validation and Analyzing of Consumption per Hour (CPH) of diesel with respect
to generator in order to manage diesel allocations within the clusters.
 Ensuring safe working condition and also enforce use of Personal Protective
Equipment.

Challenge(s) Encountered and Solution(s) Proffered

One amidst all of other challenges is meeting with clients SLAs as it concerns the clusters
under my care. This was evident with a looming case of Generators losing compression
and as such a huge accumulated long MTTR (mean time to repair) follows. A big threat
to the contract we had with our client.
However to address the situation, Proper Passive Periodic Preventive Maintenance (PPM)
on Generators, Solar panels and Back-up batteries were enforced. We as the supervisors
follow up with PPM validation and Site inspection visits; through which Snags are raised
and closed within a timeline of 48hours. Also, the teams were sensitized to take proper
ownership of the cell sites under their care and adjust their attitude to all work related
matters.

2.3 ELECTRONICS DEVELOPMENT INSTITUTE ABBA, ANAMBRA STATE

PERIOD: April 2018 – Date.
POSITION: Engineer 1

DUTIES PERFORMED:

 Data review to identify performance issues and form conclusions about products.
 Project supervision to timeline and execution.
 System modelling for improvement and redesign.

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3.0 HYBRID ENERGY SOLUTIONS

INTRODUCTION

A hybrid energy solution is the shift the renewable energy industry is witnessing with the
aim of combining multiple sources of power. Hybrid energy is necessary in countries of
unstable utility power, where daily grid power interruptions are frequent, and the use of
diesel generators or other fossil-based power sources, is a must. Hybrid energy
technologies are the answer to alternative power solutions, and to replace standby power
devices that are only used when the primary source fails.

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This sustainable energy must be diligently studied to produce a functional and effective
hybrid energy system that is economical and environmental sustainable. Designing a
hybrid energy system, addressing each customer needs, is complex and requires the
proper management of multiple and available energy sources in addition to the grid
power, such as generators, batteries, solar systems, etc.

COMPONENTS

Hybrid solution components may include:

 Solar PV systems
 Wind power systems
 Battery storage systems
 Diesel generators
 Utility grid power

For any number of integration of the above needed in a solution, a system for energy
control and management is needed; to enable the efficient implementation of hybrid
energy solution.

HYBRID ENERGY SOLUTION WITH MP INFRASTRUCTURE (eSite)

The Energy solution we implemented for the MTN Basic Transmission Sites (BTS)
project included:

 Diriflex control and monitoring system

 Diesel generators (Direct current Diesel generator DCDG)
 Battery storage systems
 Remote monitoring system
 Solar PV systems

These energy components were integrated for effective and optimized production using a
control system called DIRIFLEX and is being monitored by a Remote Monitoring
System called Site Asset Monitoring (SAM unit) unit.

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 Solar
Tenant Fuel
Camera
Battery Gen

– DC Power (hybrid and Solar)

– DC Load (Tenants)

– Fuel

– AC Utility Metering

An Ariel view of a Telecom Basic Transmission cell site

DIRIFLEX CONTROL AND MONITORING SYSTEM

The DiriflexGate
Control and Monitoring System, hereafter called Diriflex, is based on a
Lock
Linux platform. The whole integrated unit is referred to as eSite.

The Diriflex reads input from all installed sensors and connected subsystems. Based in
the read input, Diriflex will in real-time control the available actuators to maximise use of
grid and renewable energy, such as solar power, and minimise diesel generator use.

The Diriflex control algorithms also ensures that optimal battery health and lifetime is
achieved. Diriflex will log all relevant data, with a timestamp, in a local database. This
database is used for fault tracing and for sending data to eManager in case of interrupted
connection.

It is possible to update Diriflex software remotely.

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 eSite k12 DC

THE DIRECT CURRENT DIESEL GENERATOR (DCDG)

DCDG is designed to optimize the power needs, and to deliver the high currents at low
voltages. It utilizes the power for battery charging and for operating DC loads. The DC
Genset will reduce OPEX by reducing fuel consumption, eliminating the AC components
ATS and Rectifier. It is easily hybridized without any additional accessories, easily
paralleled for redundancy or scalability, and requires less frequent maintenance. It can
also be connected to the grid with a minimal cost.

Why DCDG?

Alternating current Diesel generator (ACDG), which produces Alternating current used
in homes and factories requires additional components like Automatic Transfer system
(ATS) and Rectifiers to rectify the produced AC current to DC current which is used by
Telecom equipment in Telecom cell sites. Extra cost both in purchase and maintenance is
acquired by these needed component and they also occupy space while a breakdown in
any can cause power failure.

DC generators on the other hand, produce Direct Current which is used to power the
Telecom equipment and also charge the DC battery storage systems, for effective Hybrid

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synchronization. By this process, extra maintenance cost is eliminated and space is
maximized. Note also the DCDG consumes less fuel to run when compared to ACDG.

GENSET CONTROL

eSite can control the genset in three different modes, Auto, Forced On and Forced off.
Note that these modes are different than the ones set on the genset panel. On the genset
panel Manual mode shall always be selected. If the genset panel is set to Auto mode, the
eSite will try to Force it back to Manual mode.

1. Auto

Auto is default and shall always be active when leaving the site. This mode will make
sure that eSite can start the genset when required. When eSite is running in Auto, it will
determine by itself when to start and stop the genset. This includes for instance, certain
delays and timers, in order to keep the batteries and the genset in good condition.

When working on site, genset may shut down due to the following conditions

a. Charge cycle is completed.

b. Green power influx. When Solar power, grid power or a combination can handle the
consumed power and fulfill charging criterion for the batteries. If work is done on site,
and a genset start is needed, set eSite to ForcedOn.

c. Genset shutoff, if the generator is started from the generator panel, eSite will
automatically shut down the genset after 120 minutes. To override this set the eSite in
'ForcedOn'.

2. ForcedOn

This mode may be used during maintenance or troubleshooting, when a start is needed in
order to verify the system without a charge command, i.e. when batteries are almost full,
or solar is delivering enough power to pause the genset. If 'ForcedOn' is entered, the
genset won’t turn off automatically.

3. Forced Off

This mode may be used to shut down the genset before maintenance or troubleshooting.
Emergency button shall always be pushed down when working with the genset. If
Diriflex is put to 'ForcedOff', it can’t be started automatically. Make sure eSite is not in
this mode when leaving the site. When starting the genset from eSite, either in 'Auto' or

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'Forced on'. A few additional timers are built into eSite, to make sure start and stop of the
genset is done in a proper way.

1. Warm up timer, the genset will warm up for 30 seconds and run at idle speed before
speed is started to ramp up.

2. Ramp up timer, a stable ramp up will be done from warm up speed, during up to 60
seconds.

3. Overvoltage timer, if an overvoltage is observed by eSite, it will command a lower

genset speed for a shorter time period. It is calibrated to run at 2000 RPM for 120
seconds before normal charging is re-entered.

4. Ramp down and Cooldown timers, in order to stop the generator in a safe way, eSite
has timers to take care of ramp down and cool down of the generator.

Safe mode

The DC genset is not permitted to produce power to the customer load without the battery
bank connected. This because DC gensets are not fulfilling the international standards
IEC 60950-1. Voltage ripple and voltage levels cannot be guaranteed to be within range.

Therefore if the battery breaker is tripped, eSite will command the DC genset to stop.
This will shut down customer load and eSite if neither enough solar power nor grid
power is available.

BATTERY STORAGE SYSTEM

Battery in the hybrid system serves as a store for energy. The batteries are charged when
the generator is on and discharges to carry the site load when the generator goes off.

Also, depending on the capacity of the solar system installed and the intensity of the sun;
the solar can also charge the battery during the day and in turn the battery alone works at
night.

Features to take note of when sourcing for Battery storage system;

a. Charging cycle: the number of times a battery can be charged/discharged over its
lifetime. Batteries have different cycle lives.

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 b. Battery life: all batteries will lose storage capacity over time, some faster than
others. Battery storage capacity and battery life are also impacted by how the
battery is used and temperature.
c. Usable energy: the amount of usable energy (cycle capacity) can range from 30%
to 80% of the battery’s energy storage capacity. For example, a battery with total
energy capacity of 20kWh and a cycle capacity of 80% has 16kWh available as
usable energy. While another with 20kWh and 50% as cycle capacity, has only
10kWh available as usable energy.
d. Safety: any damaged battery is not fit for use. Technical safety in battery storage
system differs, and a correct safety management system must be ensured to avoid
putting stress on the system,
e. Temperature: different batteries are suited to different climates, as most batteries
do not like very high or very low temperatures. In installing the batteries, good
ventilation is necessary and it must be positioned to avoid direct sunlight or
exposure to weather.
f. Battery management system: the system ensures that the flow of energy in and
out of the battery does not harm it. It also ensures that the battery does not
overheat.

BATTERY MANAGEMENT

The battery charge strategy and charge monitoring is one of the most important features
for the sustained operation of eSite. The batteries are of VRLA type (lead-acid), in Partial
State of Charge Operation PSoC.

This state of operation ensures maximum energy harvesting from AC utility grid, gensets
and solar arrays.

The sawtooth pattern below describes the charging level of a typical eSite battery bank in
actual operation.

A genset driven charging sequence from left to right:

 A full charge cycle increases the charging level until charging level reaches a
maximum point
 The genset is stopped; the charge level is reduced by the site load
 The genset starts again, when the charge level has dropped by approximately
30%
 This sequence is then repeated until the next full charge cycle.

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 Charging level of a typical eSite battery bank in actual operation.

REMOTE MONITRORING SYSTEM

RMS is a remote power management system that allows the operator/ISM to fully
manage and maintain the network infrastructure remotely.

It provides the ability to monitor all power and fuel related issues including but not
limited to:

 Generator control
 DC power Monitoring and Management
 Utility Grid Power Management (PHCN Power Management)
 Environmental monitoring
 Fuel Management - Fuel levels and accurate consumption
 Highlights any abnormalities with excessive fuel usage (theft!!)
 Site security
 The ability to identify problematic sites before deploying field staff - Avoids
unnecessary call outs.

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SOLAR PV SYSTEM

SOLAR MANAGEMENT

The Diriflex can control up to 3x3kWp of solar arrays. The system will automatically
detect how many arrays are connected and will continuously sweep the voltage range for
maximum power point tracking (MPPT). The Diriflex will also set the output voltage
from the solar power converters to match the desired battery charge voltage. It will also
monitor the array and power electronics for errors and send alerts to the eManager system
if any errors are detected.

The system allows for multiple power sources to be active at the same time and will
prioritize green power influx into the system. In such case the system will either lower
the demand from grid power or shutting down the genset backup power to increase the
green power harvesting.

4.0 OVERHAULING OF 20KVA DIESEL GENERATOR SETS (MTN

AWKA BACKBONE)

The power generating sets was 400Series Perkins Engine 4 Cylinders.

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 The generator was splitting oil from the engine air-breather whenever it was
in operations and I recommended complete overhauling since the engine had
put in over 14000 run hours.

PROCEDURE:

The engine was dismantled with the cylinder head, Piston and Con-Rod,
Crank-shaft removed.

The crank shaft was taken for gauge and it was found to still be at Standard.

The cylinder was pressure test for any form of deform but it was tested OK.

Two of the Pistons had ruptured and these were replaced.

The cylinder was grounded with both hard and soft grinding paste and it was
kitted properly with the valves (inlet/exhaust) in place.

The piston was soaked with diesel/detergent earlier and it was washed with
all grooves clear of carbon. Sleeve lining is still in good condition.

Pistons were fitted with piston rings; the piston rings perform two functions
as stated below.

a. To provide a gas seal between piston and cylinder bore, it enables the
optimum compression ratio is achieved and all power created by combustion
is transferred to the crankshaft.

b. Secondly, piston rings control oil flow by allowing oil to reach the top ring
which scrapes oil downward to lubricate the other rings. It also prevents oil
from passing into the combustion chambers.

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 Crankshaft was mounted back and so also the piston with his main and metal
bearings connected at the con-rod. The cylinder head was tightened with
torque wrench and valves setting done.

Engine oil and filters were all put in their respective places.

PROBLEMS ENCOUNTERED AFTER OVERHAULING

a. The Engine did not start

b. Engine oil returning into the radiator after starting.

SOLUTIONS PROVIDED

a. The engine did not start because I did not get the connection of the nozzles
pipe right for the firing order; it was corrected as thus 1-3-4-2.

b. Engine oil returning into the radiator: This gave me a lot of troubles before
getting the fault. The oil cooler device on the engine was defective, there
was a hole in it and the oil was coming from there and back into the water
part of the engine then into the radiator. The oil cooler was replaced.

4.1 BILL OF ENGINEERING MEASUREMENT AND EVALUATION

FOR OVERHAULING OF 20KVA GENERATOR

S/N DESCRIPTIO UNIT RATE AMOUNT

N ₦ ₦

1 PISTON 2 15500 31000

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2 PISTON 9000 27000
RINGS 3
3 METAL SET 8000 8000
BEARING
4 GRINDING SET 500 500
PASTE
5 CYLINDER 1 5000 5000
HEAD TEST
CRANKSHAF 1 8000 8000
6 T TESTING
FRONT/BACK 1 14000 14000
7 OIL SEAL
8 ENGINE OIL 30LTRS 15000 15000

9 FUEL/OIL SET 8000 8000

FILTERS

10 LOGISTICS 70,000

₦186,500
GRAND
TOTAL

5.0 CONCLUSION AND RECOMMENDATIONS

Conclusion

Efficient use of appliances both home and industrial is dependent on reliable

power supply systems. This report is primarily concerned with the
application of portable or standby generating sets as a power source for

23
 home and industrial purposes. Procurement, installation and maintenance
procedures will be important information and guide to clients that currently
own or wish to procure a generating set. Implementing the procedures is a
cost effective means of owning and maintaining generators. My experiences
in the practice of engineering cutting across the Mechanical and Electrical
fields has improved my competence, over the years I was able to merge the
class room work with the practical experience garnered in the field that
make ones a successful Engineer.

Recommendations

a. Preventive maintenance rather than breakdown maintenance should be carried

out promptly on Diesel Generators.

b. The use of the specified spares should always be adhered to as this always
ensures smooth operations of generators

c. Clients are always advised to ensure that all safety devices on generators are in
good working condition

d. Clients are always advised to not use adulterated fuel in operating their
generators as this always results in serious damage to the generators

e. Local Engineers should be encouraged to be part of the nation building as

we have all what it takes to make Nigeria better.

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