CHAPTER ONE

INTRODUCTION TO STUDENT’S INDUSTRIAL WORK

EXPERIENCE SCHEME (SIWES)
The Student Industrial Work Experience Scheme (SIWES) is an accepted skills program
which forms part of the approved academic standards in the degree program for Nigerian
Universities. In 1974, the Federal Government of Nigeria introduced the national policy on
Industrial training, called the Students, Industrial Work Experience Scheme (SIWES). This
program is under the umbrella of the Ministry of Education through the Industrial Training Fund
(ITF), was designed to help students acquire the necessary practical education/experience in their
fields of study and other related professions.
This is an effort which was created in order to bridge the existing gap between the theory
taught in the classroom and practice of science, agriculture, medicine, engineering, technology
and other professional programs in the Nigerian tertiary institutions. This program is aimed at
exposing the students to the use of various machines and equipment’s, professional work
methods and ways of safeguarding the work areas in industries as well as other organizations and
parastatals. The program was established basically to impact elaborate practical understanding to
students with respect to their various disciplines. It is also intended that the student through a
process of relation to academic knowledge and practical industrial application would understand
the underlying principles and become better focused and acquire the practical applications
towards excellence in his or her discipline.

1.1 MEANING OF SIWES

The five capitalized letters SIWES stand for the Student Industrial Work Experience Scheme
that was created to help students from Nigeria get practical knowledge and wide horizons based
on their future profession while they are still studying at the university.

1.2 HISTORY OF SIWES

At the early stages of the development of education in Nigeria, there was a problem of the gap
between theory and practical skills of students. Therefore, there was a need to give students the
opportunity to get real work experience.

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The program was created to give student experience in addition to theoretical learning. The
industrial training policy was introduced by Federal Government of Nigeria in 1973. This was
necessary to improve practical skills of students. SIWES has become a necessary pre- condition
of graduation. The program is working with such disciplines as engineering, medical science,
natural science, technology, agriculture, education, environmental, applied science.
The duration of the program can be different, for the universities it's six month, and a year for
college and polytechnics.
The program is developed under the guidance of the Ministry of Education. This is an excellent
bridge between theoretical and practical education. SIWES is working on designing proper
programs for exposing students to the industrial workplace environment. It is all about the
development of occupational competence.

The main goals of the creation of SIWES are:

1. Introduce students to real work atmosphere so that they know what they would most
likely meet once they graduate.
2. Help students get important contacts for their future jobs. Let students work with real
technology and gears that are not present in their institution.
3. Allow students develop industrial skills they would need after graduation. Simplify the
transition from higher educational institution to the workforce.

1.3 IMPORTANCE OF SIWES

This has become an incredible program for all tertiary institution students. SIWES gives a unique
opportunity to be introduced to the industrial environment and obtain the technical knowledge
while studying.
SIWES is coordinated by the Industrial Training Fund (ITF) and NUC and thus is under the
umbrella of the Ministry of Education. This bridge between the institutions, students, and
industries should make the difference and bring positive changes in the future.

1.4. AIMS AND OBJECTIVES OF SIWES

1. To provide students with industrial skills and needed experience while the course of
study;

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 2. To create conditions and circumstances, which can be as close as possible to the actual
workflow;
3. To prepare specialists who will be ready for any working situations immediately after
graduation;
4. To teach students the techniques and methods of working with facilities and equipment
that may not be available within the walls of an educational institution;
5. To give students the ability to try and apply the given knowledge.

The objectives of SIWES program are all about strengthening future employees. Such
program is successful attempt to help students to understand the underlying principles of their
future work. After passing the programs, the student can concentrate on the really necessary
factors of his or her work.
Referring to the feedback of students, the experience of participating in the program has
become very useful for them. Employers also note a higher level of skills of such students.
1.5. BENEFIT OF SIWES
1. Opportunity for students to blend theoretical knowledge acquired in the classroom with
practice hands-on application of knowledge required to perform work in industry.
2. Exposure of students to the environment in which they will eventually work, thereby
enabling them to see how their future professions are organized in practice.
3. Minimization of the bewilderment experienced students, particularly those from a non-
technological background, pursuing courses in science, engineering and technology
with regard to different equipment, processes, tools etc. available in industry.
4. SET students appreciate work method and gain experience in handling equipment and
machinery which may not be available in the institutions.
5. Preparing students to contribute to the productivity of their employers and national
development immediately after graduation.
6. Provision of an enabling environment where students can develop and enhance person
attributes such as critical thinking, creativity, initiative, resourcefulness, leadership,
time management, presentation skills and interpersonal skills, amongst others.
7. Preparing students for employment and making the transition from school to the world
of work easier after graduation.

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 8. Enhancing students’ contacts with potential employers while on training.
9. Enabling students bridge the gap between the knowledge acquired in institutions and
the relevance production skills (RPSs) required in working organizations.
10. Making SET students appreciate the role of the professions as the creators of change
and wealth and indispensable contributors to growing the economy and national
development.

ADVANTAGES OF SIWES
i. First-hand experience working as an engineering professional.
ii. Cover your technical knowledge and engineering process to a real-life position.
iii. Work with other engineering professionals.
iv. Experience what it’s like to work in a professional organization.
v. Increase your technical, interpersonal and communication skills, both oral and written.
vi. Observe interactions of engineers with other professional groups.
vii. Witness the functioning and organization of business and companies.
DISADVANTAGES OF SIWES
 Being Treated as an Assistant
Probably heard that interns often spend their days getting coffee, running errands, making
copies and performing other menial tasks. That’s because many companies take advantage of
interns and see them more like slaves or assistants than prospective employees.

 Low Earning Potential

Internships often have very low earning potential. Unlike an appropriate, full-time job,
highest paid internships don’t tender a combative conduct to try and engage talent. Interning for
the wrong company could leave you in a very be bad financial situation.

 Increases Your Market Value

A frequent problem many graduates surface is that they’re afford a lot less than someone with
familiarity to do the same job.

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1.6 HISTORY, ACTIVITIES AND ORGANISATION OF THE TRAINING
ESTABLISHMENT

 INTRODUCTION

This presentation is based on the experience gained during my six months Industrial Training
Zobis Cable Company Okoti iyowa odekpe, the presentation highlights the brief history of Zobis
Cable Company, they deal in with the production of electrical wire. It describes the activities of
my experience during the industrial training and the relevance of the training to my field of
study.

 BRIEF HISTORY ZOBIS CABLE COMPANY

Zobis Cables Nigeria Limited has become a household name and a significant player in the
electrical manufacturing industry.
It was registered as a trading company in 2006 and due to its exceptional performance over the
years, has extended its portfolio to civil and mechanical engineering with the establishment of its
first affiliate company called John Zobis Engineering in 2010.
John Ezeobi, a university student from a middle-class family, founded the company in
2006.
I started the company from the little savings I had while in school, which was one thousand,
three hundred and fifty naira only (N1,350) in the year 2006,” he tells us.
With an eye for quality, he made his first supply, netting a profit of N8,000. Zobis Cable today
stands tall among the giants of the industry.
When you make mention of top names in the industry today, Zobis Cables will be mentioned.
We are one of the largest in the southeast and the south-south in terms of capacity in cable
manufacturing in Nigeria today,” Ezeobi proudly asserts
Their vision extends beyond accolades, and as such, they are yet to accept any awards. “We have
a vision of a bigger place,” Ezeobi explains.
zobis has an impressive resume, having worked with oil servicing companies, military outfits,
and several prominent organisations. Their current endeavour involves expanding the factory to a
1,000 metric tonne capacity with different sizes of cables – a significant investment set to
generate employment for around a thousand individuals.
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A statement noted that community engagement is at the heart of their operations. Located in
Okoti in Anambra State of Nigeria, Zobis has continually given back to the community through
building houses for the less privileged, and has also created a proper road and drainage system to
combat flooding and he intends to do more.
Ezeobi said his inspiration is to provide Nigeria with quality cables: “I want Nigeria to be known
for good quality cables. When you go to the market, you see a lot of fake and low quality cables
which has been the leading cause of fire outbreaks and other electrical incidents and most times
has led to loss of lives and properties.
Our company thrives on sustainable and quality products. We give quality for less stress
and less cost,” he states passionately.

Fig 1.6.1: Company’s Organization Chart

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 CHAPTER TWO
CABLE PRODUCTION
2.1 INTRODUCTION TO BARE CONDUCTOR CABLES
Bare conductor cables are widely used in the power transmission and distribution
industry. Unlike insulated cables, bare conductor cables do not have any insulating layer, which
makes them ideal for outdoor applications like power lines and substations. These cables are
essential for carrying electrical current over long distances with minimal losses.
Usage Scenarios: Bare conductor cables are primarily used in overhead power lines, substations,
and grounding systems. They are suitable for areas where insulation is not required or where
environmental factors do not pose a significant threat to the integrity of the conductor.
How They Work: The primary function of bare conductor cables is to conduct electricity. They
rely on their conductive material, usually aluminum or copper, to transmit electrical current from
one point to another. The lack of insulation allows for better heat dissipation and reduces the
weight of the cable.
Features:
• High Conductivity: Materials like copper and aluminum provide excellent electrical
conductivity.
• Durability: These cables are designed to withstand harsh environmental conditions.
• Cost-Effective: The absence of insulation reduces manufacturing costs.
• Easy Installation: Lighter weight and flexibility make them easier to install compared to
insulated cables.
Disadvantages:
• No Protection Against Short Circuits: Lack of insulation can lead to short circuits if not
properly managed.
• Exposure to Environmental Elements: Vulnerable to environmental factors like wind, rain,
and corrosion.
• Limited Use Cases: Not suitable for applications where insulation is necessary for safety
reasons.

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2.2 TEST CARRIED OUT ON A BARE CONDUCTOR
There are four set of test carried on a bare conductor/wire of any diameter brought from
UZ series machines so as to ensure their quality right from the beginning stage of production. If
this conductor/wire is tested and found to be good, then it will now be release for further process
so as to continue with the ongoing operation. And if happens to be bad, the conductor/wire will
be rejected so that it will be taken to smaller UZ series machines to use it and draw a new
diameter below the rejected diameter.
The test to be carried on the bare conductor /wire are as follows:
1. DIAMETER TEST
This test is carried on the bare conductor/wire using Vernier caliper or micrometer. But
the most used device in the quality control laboratory to carry out the diameter test is the
micrometer. This micrometer has an opening where the sample is placed so as to obtain the
diameter reading of the conductor/wire, and this opening is controlled by the handle of the
micrometer when it's rotated up direction, the opening tends to be widened and when it's rotated
to the down direction the opening tends to be shortened.

Fig 1: Micrometer

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 Since the company are producing their cables as based on standards, the company has
different standard ensured diameter before concluding the drawn diameter to be good or bad.
Some of this standard diameter can be seen on the table below:
SIZE OF CONDUCTOR DIAMETER OF CONDUCTOR
S/N
(mm2) (mm)

1 1.0 1.13

2 1.5 1.35

3 2.5 1.73

4 4.0 2.22

5 6.0 2.72

Table 1: Standard Diameter Test

2. RESISTANCE TEST
The resistance test is carried out on the conductor/wire so as to prove the accuracy of the
conductor/wire diameter tested. This is achieved using the law that relate the conductor diameter
and the resistance, this law says that when the diameter of a conductor is less, its resistance will
be high and when the diameter happens to be high, then the resistance will be low.
The quality control department uses a device called "resistomat" to carry out resistance test. The
resistomat has a resistance bridge which collect the sample to be tested and the reading is
displayed on the display unit (screen of the meter) of the resistomat. This displayed result is
termed as the measured value but not the actual value, the actual value is obtained by multiplying
the measured value with the standard temperature correction factor (TCF) value provided at each
temperature of taking the resistance measurement. This result due to temperature being one of
the factors affecting the resistance of a conductor, and this factors are:
viii. Temperature
ix. Nature of material e.g. copper, aluminum, steel etc.
x. Length

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xi. Area

Fig 2: Resistomat
2.3 STEPS ON HOW TO CARRY RESISTANCE TEST USING
RESISTOMAT
 Connect the equipment to the source of supply.
 Push the power switch to “ON” the equipment.
 Connect the current terminals +1 and -1 on the instrument via the connecting leads to the
terminal where the sample is connected. While the voltage terminal terminals of the
instrument +U and -U to the base of the resistance bridge.
 Connect the sample via the connecting leads to the terminal.
 Note the reading on the display of the equipment and record on the appropriate form.
 Switch “OFF” the equipment at the end of the test.

Like the diameter test, the resistance test also has a standard value (S.V) of resistance for each
size of a conductor. This standard values are to be compared to the measured ones so as to
provide conclusion of the result just as in diameter test. Some of this resistance standards values
are seen in the table below:

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2.4 TABLE OF MAXIMUM RESISTANCE OF A CONDUCTOR
SIZE OF CONDUCTOR
DIAMETER OF
S/N CONDUCTOR MAXIMUM
CONDUCTOR (mm)
(mm2) RESISTANCE (Ω)

1 1.0 1.13 18.1

2 1.5 1.35 12.1

3 2.5 1.73 7.41

4 4.0 2.22 4.61

5 6.0 2.72 1.15

3. WEIGHT TEST
The weight is measured at 1-meter length (1000mm) of the brought sample from the UZ series in
the factory, the length is measured using a steel rule provided in the laboratory. After preparing
the weight sample, the sample is placed on a machine called "weight balance machine" which
gives the result on its display unit.

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 Fig 3: Weight Balance Machine
The measured weight is also enough to tell whether the drawn diameter of the conductor/wire is
lesser/higher than the standard diameter planned to draw. From the table of standard weight
values, it happens that if the measured weight is below the standard weight value of that
particular size of conductor/wire, then the drawn diameter is not up to the standard diameter to
draw, and when it goes much above the standard weight then in we say the diameter is high.
Some of this standard weight from the standard weight table can be seen on the table below:

2.5 STANDARD WEIGHT TABLE

SIZE OF
DIAMETER OF CONDUCTOR MIN. WEIGHT OF
S/N CONDUCTOR
(mm) CONDUCTOR (g)
2
(mm )

1 1.0 1.13 8.92

2 1.5 1.35 12.74

3 2.5 1.73 20.92

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 4 4.0 2.22 34.42

5 6.0 2.72 51.66

4. ELONGATION TEST
The elongation test is a test carried out on the bare conductor/wire to know the level of annealing
present in the conductor/wire. The annealing refers to the flexibility of the conductor/wire which
allows it to response to whatever shape or direction it's turned, and the conductor/wire possess
the annealing (flexibility) during drawing process by passing through the annealing chamber on
UZ series machine. The annealing chamber carries heat at very high temperature which allow or
makes the conductor or wire to be soft (i.e. to reduce the hardness in it) so that it can give
response to whatever shape it's turned without returning back.
The elongation test is measured by an elongation test machine which has an upper and lower jaw
chuck that clamp the sample between its two end and draw it until it breaks. This sample to break
is prepared by marking a length called "sample length" and the "gauge length" on the sample by
using steel rule. The sample length is prepared for the machine's jaw chuck to hold and its
prepared length is 25mm at both ends, while the gauge length is the initial length used to carry
the elongation and the measured gauge length is 250mm. After breaking the sample, the new
length (i.e. the increase in length caused by the machine after applying tensile force on the
sample) is referred to as the final length.

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 Fig 4: Machine's jaw chuck
The percentage elongation (℅S) is obtained using strain (Ɛ) equation provided by hook's law
which is shown below:

%S =

Where, L1=Initial length (250mm)

L2 = Final length

%S= Percentage Elongation

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The standard minimum elongation for the conductor is 18.0% for 1.0mm2, and any area above
1.0 mm2, its standard minimum elongation is 22.5%.

Finally, the standard of production of the drawing operation is as according to (NIS IEC 60228),
or (NIS 159).

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 CHAPTER THREE
CONDUIT WIRING CABLE (NCY CABLE)

The conduit wiring cables are cables used in pipe wiring, the pipes are mounted inside the wall

of a building and the cables are run in to the pipes. The conduit wiring cables are cables with

only PVC (polyvinyl chloride) insulation on them which is provided an extruder machine so that

to protect the users against the shock of electric current in their building.

The PVC insulation stage is a stage that follow after the drawing stage and the insulation

operation is carried by an extruder machines which are referred to "US series machines" in the

NOCACO factory. For a conduit wire cable, the insulation stage serves as the finishing stage of

production, while for other type of cable (such as surface wiring cable etc.) are released for

further process so as to carry the next operation on the cable.

The conduit wiring cables are called NCY cables where the "N" representing the standard of

cable production, "C" is representing copper conductor material, and "Y" representing the PVC

16
insulation that covers the bare copper conductor. Example of this cable include NCY 1×1.0mm 2,

NCY 1×1.5mm2, 1×2.0mm2, 1×4.0mm2 etc.

3.1 TEST CARRIED OUT ON THE CONDUIT CABLES

The quality control department provide a set of test for their conduit cables which are all

according to national and international standard. The test provided for the bare conductor on

drawing stage are all provided here in PVC insulation stage with an additional in PVC weighing

and conductor elongation test. During weighing of conductor, sample for both conductor and

PVC are prepared for weight, and three (3) sample is also provided for elongation test to test the

annealing presence.

After all this, three sample is provided for the design test of the PVC insulation which is carried

by a machine called "profile projector machine". The samples are prepared using razor blade to

cut a very thin portion of the round PVC and take them to the machine with an aim of measuring

sample wall thicknesses and the diameter over the PVC insulation for each sample, and each of

the sample is to carry four wall thicknesses and two diameters over as seen below:

S1

S3
Diameter over (ɸ1)
S4

S2

Diameter over (ɸ2) 17

Where, S = wall thickness

ɸ = Diameter over

3.2 THE PROFILE PROJECTOR MACHINE

The profile projector machine has two switches to ON before starting the machine, the first
switch is for the projector on the machine and its provided light which helps the user to see the
projected sample on the round portion of the machine where X and Y axis are located, while the
other switch belongs to the meter (i.e. a section of the machine that display the axis reading)
which has two display unit that display the readings of both X and Y axis carried on the machine.
The machine also has a small portion with round glass for receiving any sample to test, and the
projector is placed on top of the glass facing it so as to project whatever sample place on it.

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 Fig 5: Profile Projector Machine
After measuring all three samples, a total average of all the sample is obtained for both wall
thicknesses and diameter over and compare them with their standard values so that the cable will
be released for coiling and packaging (i.e. if happened to be good all measurement) and the
record of measurement are filled in its appropriate form, but if the measured values did not obey
the desired then the cable rejected. The reason for the design test is to ensure that the insulation
that covers the bare conductor is well insulated in such a way that that the thinnest portion
among the wall thicknesses and diameter over are above the desired so that the cable will not
easily failed during time of usage.

STEPS ON HOW TO CARRY DESIGN TEST USING PROFILE PROJECTOR

 Connect appliance to source of supply.

 Switch ON the appliance as well as digital counter display.

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  Put sample on the rotational round sample holder.
 Enclose the testing environment with the help of the curtain provided on the appliance
 Manipulate the two rotational handles attached to the sample holder.
 Note the readings on the digital display
 Switch OFF machine at the end of the test.

3.3 SURFACE WIRING CABLE (NCYY CABLE)

The surface wiring cables are cables used for house wiring and are fixed externally to the surface
of the wall of the building by making use of clip. This surface wiring cable contain sheathing
which serves as a protection to the two cores (red & black).

TEST CARRIED OUT ON THE SURFACE WIRING CABLE

The surface wiring cable receives all the test carried on the conduit wiring cable excluding the
design test of PVC insulation of the two cores (red & black). In addition to the test, the design
test of PVC sheathing of the cable is carried using the same profile projector machine by
measuring six wall thicknesses and two diameters over (minor × major) so as to ensure the
quality of the PVC sheathing. The design test of the PVC sheathing is illustrated on the diagram
below:

S1 S3

S5 S6

S2 S4

Major

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The design test of the PVC sheathing also has the same procedure of carrying the measurement
as in PVC insulation stage stated in conduit wiring cable. After all measurement are carried out
and the cable found to be good, then the cable is released for coiling stage and the records of all
measurement are filled in the appropriate form just as in the case of PVC insulation stage.

3.4 INSULATION RESISTANCE TEST AT CONSTANT (K)

The insulation resistance test at constant (K) is a test carried on PVC insulation and PVC
sheathed stage of a cable so as to test the quality of the PVC insulation of the cable. The test is
carried in water bath that is filled with water at 70 0C after placing 5 meters of the PVC insulated
cable in the water bath (in coiled form) for not less than 2hrs. The insulation resistance
measurement is carried out by using either a tera-ohm meter device (which will be discuss later
under the power cable section) or an insulation tester, but the insulation tester (meter) is mostly
used in carrying the measurement in the quality control lab.

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 Fig 6: Tester

At time of measurement, the neutral terminal of the insulation tester is connected to the body of
the water bath which as earth to the device, while positive is connected to the cable to be tested
and then the following procedures are followed:

 ON the meter and set the pointer at 2500v.

 Press "Select" on the meter.
 Click on "Test V" and ensure that the selected voltage level is at 500v
 Click and hold the start button for 2 sec and release.
 The meter will read some second and display the insulation resistance result.
 Record the result in its appropriate form
 Remove the connections and off the meter.

The actual value of the result is obtained by computing the below formulae.
Measured value × Length
Actual insulation resistance at constant (K) =
1000
This actual value of the insulation resistance is also recorded in the form after compared with the
standard minimum insulation resistance value at constant (K), and seen to be a valid result.

INSULATION RESISTANCE TABLE AT CONSTANT (K)

S/N AREA (mm2) CONSTANT (K)

1 1.0 0.011

2 1.5 0.011

3 2.5 0.010

4 4.0 0.0085

5 6.0 0.0070

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FLEXIBLE CABLE

The production of the flexible cable originated from the drawing operation carried by UZ2, UZ4,
or UZ9 in the factory where they draw a very small diameter such as 0.25mm, 0.5mm etc.
depending on the application of the flexible cable to be produced, the UZ series machine will
draw a set of spools of the flexible wire as demanded in the cable design form. This set of spools
are taken to UC2 machine where it collects all the spools and bunch them together to form
another diameter as seen from the diagram below:

The test carried on the flexible cable include the diameter test, counting number of strands of
bunched wire to ensure its completed and lastly, measuring the resistance of the bunched wire to
confirm standard and then keeping record of all measurement.

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POWER CABLES (ARMOURED (NCYRY) & NON ARMOURED CABLE (NCYY-R))
The power cables are cables used at a voltage level of 600V - 1000V. The cable's application are
mostly found in:
 Underground transmission/distribution of electrical energy.
 Drawing of supply to heavier machine that consume much energy.
 And sometimes, in the transfer of electrical energy from pole to building.
These power cables include Armoured and non Armoured cable which are been described by
NCYRY and NCYY-R cable respectively. Each alphabet in the cords has a meaning that it
represents in the process of producing the cable, this cords and their various categories are listed
below with their names.
 Armoured cables (NCYRY).
 NCYRY: N is representing the National & International standard of production, C is
representing that the conductor is Copper in nature, Y representing the insulation that
covers the bare conductor (red, yellow, blue, and black), R representing the cable is
round in shape, and the last Y is representing the inner & outer sheath of the cable.
Example of this cable includes NCYRY 4 × 2.5mm 2, NCYRY 4 × 4.0mm2, NCYRY
4 × 6.0mm2, NCYRY 4 × 10mm2, NCYRY 4 × 25mm2, NCYRY 4 × 35mm2, etc.
 NCYRYs: Copper conductor, PVC insulated, PVC sheathed single core cable.
 NCYRYm: Copper conductor, PVC insulated, PVC sheathed, multi core cable.
 NCYRYcc: Copper conductor, PCV insulated, PVC sheathed, control cable.

 Non Armoured Cable (NCYY-R).

 NCYY: The non armoured cable cord has the same meaning with that of the
armoured cable, what differs the two is that for non armoured cable, R is not included
in the cord.
Example of this cable include NCYY 4 × 2.5mm 2, NCYY 4 × 4.0mm2, NCYY 4 ×
6.0mm2, NCYY 4 × 10mm2, NCYY 4 × 16mm2, NCYY 4 × 25mm2, NCYY 3 ×
35mm2, etc.

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  NCYYcc: Copper conductor, PVC insulated, PVC sheathed, control cable.
 NCYYm: Copper conductor, PVC insulated, PVC sheathed, multi core cable.
 NCYYs: Copper conductor, PVC insulated, PVC sheathed, single core cable. Etc.

The Armoured and Non Armoured cable also passes through several stages of protection. The
cable is coiled in a big iron/wooding drum, and at each production stage the cable (in drum) is
carried by a fork lift machine to the quality control department to undergo different test so as to
ensure its quality at that particular stage of production rather than at end.
The production stages of the power cables are shown below:
I. Drawing stage: Carried by UZ series machine.
II. Conductor stranding stage: Carried by UC series machine.
III. Insulation stage: Carried by US series machine.
IV. Core stranding stage: Carried by UE series machine.
V. Inner sheathing stage: Carried by US series machine.
VI. Armouring stage (in case of armoured cable): Carried by UE series machine.
VII. Outer sheathing stage: Carried by US series machine.

3.5 THE TEST CARRIED ON POWER CABLES

The quality test of the power cable is carried based on the stages of production of the cable,
which are:
 Conductor drawing stage:
 Conductor resistance test
 Diameter test
 Weight
 Elongation test
 Conductor stranding: At this stage, the conductor is still a bare conductor. Hence, it does
not undergo any further test.
 PVC insulation stage:
 Conductor resistance test
 Diameter test

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  Weight of both conductor & PVC at 1-meter length.
 Design test of the PVC insulation.
 Insulation resistance test at constant (K).
 Core stranding stage:
 High voltage test (HVT)
 Conductor resistance test
 Insulation resistance
 Inner sheathing stage: At inner sheathing stage, the cable is shifted to the armouring stage
because at outer sheathing stage, both the inner sheath and outer sheath are tested.
 Armouring stage: This stage only occurred on armoured cable. It refers to a stage where
the inner sheath of the cable is surrounded by steel wires which serves as protection to the
cable. At this stage of production, the quality control department carried only high
voltage test (HVT) on the cable.
 Outer sheathing stage:
 Conductor resistance test
 Insulation resistance test
 Diameter test on armouring (If it's an armoured cable)
 Design test of both inner & outer sheath

 CONDUCTOR RESISTANCE TEST

The conductor resistance test of a power cable is totally different from that of wiring but uses the
same resistomat device to carry the measurement. Their connection differs because the power
cable is on drum and is tested in a cage (testing area) outside the lab. The issue now is that the
two ends of the cable cannot be taken in to the lab, these allowed the use one end of the cable
( by passing it in to the lab through a small window) and tight all cores on other end. Since the
resistance bridge on the resistomat has two clamps that hold the two ends of sample to be tested,
then two cores are used at a time to carry the resistance test and finally, the resistance measured
value (M.V) is divided by two in order to have the reading for one core.

The actual resistance value of the measurement is obtained by computing the below formula
because, temperature and length are among the factors that affect the resistance of a conductor.

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 M .V
×TCF ×Constant
Actual value (A.V) = 2
Length
Where, M.V= Measured Value
TCF=Temperature correction factor
L= Length
Constant =1000

 INSULATION RESISTANCE TEST

This is a test carried on the cable to ensure the quality of the PVC insulation. The test is carried
by tera ohm meter device. The tera ohm meter has two terminals (positive & neutral) and it
display result in mega ohms (MΩ).

Fig 7: Tera Ohm Meter Device

It also has similar way of connection like that of conductor resistance. In this case, one of the end
is left open (all cores are separated), while other end is taking in to the lab. When conducting the
test, one core is connected to positive terminal and the remaining cores are tight up together and
connected to the neutral. This connection is repeated interchangeably starting from red, yellow,

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blue, and then the black core. The M.V of each core is displayed on the display unit of the tera
ohm meter after carrying the following steps:
 Connect one of the test leads to the +ve terminal of the instrument and the other lead to
the –ve terminal.
 Connect the other end to the +ve lead to the sample in water, and the –ve to the body of
the water bath.
 Switch ON the unit and allow the system to come on after undergoing a system check.
 Press the MENU key.
 Press the right arrow key → twice.
 Press the down arrow key ↓ once.
 Press the ENTER key.
 Scroll with the down arrow key ↓ to highlight the 419 submenu.
 Press the ENTER key.
 Press the right arrow key → to access the already saved test set-up.
 Press the START key to carry out measurement.
 Record the result after the RED indicator light is OFF.
 Switch OFF the unit.

Like the conductor resistance, the insulation resistance actual value (A.V) is obtain by computing
the below formula.

M . V ×TCF × Length
A.V =
Constant
Where, Constant = 1000

 HIGH VOLTAGE TEST (HVT)

The high voltage test is carried on both power & wiring cables for the detection of fault on cable.
For wiring cables the HVT test is carried in water because of its low voltage level capacity, while
power cables are connected directly to the HVT machine by placing the drum inside cage
(testing area) and allow one end of the cable open (i.e. all cores are separated including
armouring), while the red core from other end is connected to the positive terminal of the HVT
machine and the remaining cores (including armouring) are connected to the negative terminal.

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After all connections, the test is carried out using HVT machine to send a voltage of 3.5KV in to
the cable. If the cable is able to withstand the voltage for a duration not less than 5 minutes, then
the cable will be released for further operation after passing all possible measurement, otherwise
the cable is rejected.

Fig 8: High Voltage Machine

 STEPS ON HOW TO CARRY A HIGH VOLTAGE TEST USING HVT

MACHINE
 Connect sample to be tested to the terminals inside the cage (testing area) and close the
cage to ensure complete circuit.
 Connect test equipment to source of power supply.
 Turn the key clockwise. Press it anti-clockwise then release.
 Turn the control knob to Ein (ON) position.
 Press the red button to energize the system.
 Press and hold the “spanning steight button” until the desired set voltage is reached.

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  DE-ENERGIZING
 Press and hold the “spanning fall button” until the pointer on the voltage display goes
back to “0”.
 Release the red button switch.
 Turn control knob to “Aus” (OFF) position.
 Release the key
 Switch OFF the equipment at the close of working hours.

 REASON WHY HVT TEST IS CARRIED

The high voltage test (HVT) is carried on the power cables to detect the following:
1. Open circuit in the cores
2. Short circuit
3. Leakage of current

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 CHAPTER FOUR
CONCLUSION AND RECOMMENDATIONS
4.1 CONCLUSION
In conclusion, my industrial training experience in the quality control unit, Zobis Cable
Company Okoti iyowa odekpe has been invaluable in bridging the gap between theoretical
knowledge and practical application. Throughout the training, I gained hands-on experience in
various aspects of electrical knowledge, including cable production. This experience has not only
enhanced my technical skills but also instilled in me a sense of professionalism and
responsibility.

4.2 DIFFICULTIES ENCOUNTERED DURING INDUSTRIAL TRAINING

PROGRAMME
It was very difficult for me to find a place of attachment because most hospitals and
laboratory find it very difficult to accept microbiology student and most of them prefer one-year
training and full time staffs. it was also difficult for me cater for my transport fare because of the
distance between my place of work and where I live and they don’t give stipends to student.

4.3 RECOMMENDATION
I recommend that SIWES should organize and plead to industries the essence of assisting
students and ability to give them the opportunity to assess and learn as much as they can so they
be able to achieve their aim.

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