See discussions, stats, and author profiles for this publication at: https://www.researchgate.net/publication/363672669 STUDENT INDUSTRIAL WORK EXPERIENCE SCHEME (SIWES) REPORT Technical Report · June 2021 DOI: 10.13140/RG.2.2.31849.36967 CITATIONS READS 0 548 1 author: Onyedikachi Ofordile University of Lagos 1 PUBLICATION 0 CITATIONS SEE PROFILE All content following this page was uploaded by Onyedikachi Ofordile on 20 September 2022. The user has requested enhancement of the downloaded file. A TECHNICAL REPORT ON STUDENT INDUSTRIAL WORK EXPERIENCE SCHEME (SIWES) UNDERTAKEN AT FORTIS ENGINEERING SERVICES LIMITED, ONIRU, LEKKI, LAGOS. BY OFORDILE ONYEDIKACHI CYPRIAN MATRIC NUMBER: 170406516 SUBMITTED TO THE DEPARTMENT OF METALLURGICAL AND MATERIALS ENGINEERING FACULTY OF ENGINEERING UNIVERSITY OF LAGOS, AKOKA, YABA, LAGOS IN PARTIAL FULFILLMENT OF THE REQUIREMENTS FOR THE AWARD OF BACHELOR OF SCIENCE IN METALLURGICAL AND MATERIALS ENGINEERING SUPERVISOR: DR GBENEBOR O.A. DECEMBER 2021. i DECLARATION I sincerely declare that: I am the sole writer of this report. The details of training and experience contained in this report describe my involvement as a 6 months Student Industrial Work Experience Scheme (SIWES) intern at Fortis Engineering Services Limited. All the information contained in this report is certain and correct to me. NAME: Ofordile Onyedikach Cyprian MATRIC NUMBER: 170406516 SIGNATURE: DATE: 2nd December 2021 ii Fortis :Engineering Services Date: 22nd November, 2021 LETTER OF CERTIFICATION This is to certify that Mr. Ofordile Onyedikachi Cyprian, a 400 level Student of the University of Lagos, Metallurgical and Materials Engineering Department with Matric No: 170406516 has successfully completed his 6 months Student Industrial Work Experience Scheme (SIWES) internship at Fortis Engineering Services Limited from the 24th of May to the 9th of November 2021. He undertook a 5 agenda training plan that comprises of; Research and Development, Technical Presentation, Field Experience, Technical Report writing and Bid preparation. As part of the training plan, he actively participated in all the operations of the company, acquiring key experience in our core areas of specialization. During the internship he demonstrated good research and problem-solving skills with a selfmotivated attitude to learn new things. His performance exceeded expectations and was able to complete the training plan successfully on time. We wish him all the best for his future endeavors. Warm regards, Engineer Ayodeji Adetayo Head, Technical Operations Block 116, Plot 16A George Omonubi Street, Off Oniru New Market Road, Lekki Phase 1, Lekki, Lagos State Nigeria Tel: (+234)-811-891-9880Email: info@fortisengineering.net www.fortisengineering.net ACKNOWLEDGEMENT I express my sincere gratitude to God almighty, the University of Lagos and the Department of Metallurgical and Material Engineering for the opportunity availed us in undergoing an intensive 6 months Student Industrial Work Experience Scheme (SIWES). I also wish to express my sincere gratitude to the Management and Staffs of Fortis Engineering Limited for the priceless work experience I acquired in the duration of my internship. iv ABSTRACT The Student Industrial Work Experience Scheme (SIWES) is a program put in place by the Federal Government to ensure that all Science and Engineering Students in their undergraduate level obtain relevant industry experience by undergoing 6 months or 3-months internships in industries relevant to their course of study. I underwent my internship at Fortis Engineering Services Limited, an indigenous oil and gas servicing company with head office in Lagos state and operational base in Warri. The company utilizes a training plan which comprises of; Research and Development, Technical Presentation Development, Field Experience, Technical Report Writing and Bid Preparation. The training plan ensured that I obtained first-hand experience in many of the key areas peculiar to the Nigerian oil and gas industry with key focus on Research and development of new technologies, advanced field works and effective engineering business management. This Technical Report aims to explain in detail the relevant experiences acquired during my internship at Fortis Engineering and how they are related to my course of study. I highly recommend that the Student Industrial Work Experience Scheme (SIWES) be undergone twice by Engineering Students in the Institution to ensure that the students incorporate intensively the necessary skills and ability to work in the real world. v TABLE OF CONTENT Page Title Page i Declaration ii Letter of Certification iii Acknowledgements iv Abstract vi List of Tables and Figures viii Abbreviations and key words ix CHAPTER ONE – INTRODUCTION 1 1.1 Introduction to the SIWES Training Program 1 1.2 Organization History 2 1.3 Organization Structure 4 1.4 Intern’s Roles/Responsibilities and Activities 5 CHAPTER TWO – DETAILED INTERN’S ROLE/RESPONSIBILITIES AND DAILY ACTIVITIES 2.1 The Training Program 7 2.2 Research and Development 7 2.3 Technical Presentation 12 2.4 Field Experience 14 2.5 Technical Report Writing 20 2.6 Bid Preparation 23 vi 2.7 Other Relevant Experience Gained 27 CHAPTER THREE – DISCUSSION, ANALYSIS AND EVALUATION 3.1 Professional Knowledge and Competence gained 28 3.2 Description of Tools and Equipment used 29 3.3 Problems Encountered 32 CHAPTER FOUR – CONCLUSION, LIMITATIONS AND RECOMMENDATIONS 4.1 Conclusion 34 4.2 Limitations 34 4.3 Recommendations 34 REFERENCES 36 vii LIST OF TABLES AND FIGURES Fig 1.1 Fortis Value System Fig 1.2 Fortis Organogram Fig 2.1 Fortis Research and Development Framework. Fig:2.2 SNI Services Triangle Chart. Fig. 2.3 SNI SmartPIMS Pipeline installation demonstration. Fig 2.4a/b Novosound Kelpie Toolbox and Test Demonstration. Fig 2.5a/b ATEX rated pneumatic grinder toolbox and demonstration Fig 2.6 SNI smartPIMS system configuration Fig 2.7 On-site installation of SNI SmartPIMS Fig 2.8 Corrosion data reading using SNI WebPIMS Fig 2.9 PAUT Hydroform, Olympus Scanner and Diesel Tank Fig 2.10 Typical wall thickness color chart/code using PAUT Fig 2.11 Dig up and NDT testing of flowlines using PEC Fig 2.12 RVI of Heat Exchanger tubes using Borescope Fig 2.13 images from the Heat Exchanger Tubes using Borescope RVI Fig 2.14 Engineering Bidding Process Fig 3.1 SNI smartPIMS in house installation Demonstration Fig 3.2 ATEX rated Pneumatic grinding and coating removal tool. Fig 3.3 Teslong NTS300 Borescope Fig 3.4 Handheld Ultrasound Wall Thickness Gauge viii ABBREVIATIONS AND KEY WORDS ASME American Society of Mechanical Engineers ASTM American Society of Testing and Materials BOSIET Basic Offshore Safey Induction and Emergency Training COMPEX Competence in Explosive Environment EPIC Engineering, Procurement, Installation Commissioning FPSO Floating, Production, Storage and Offloading GRN Good Receipt Note HSE Health Safety and Environment IRIS Internal Rotatory Inspection System NCR Non-Conformance NDT Non-Destructive Testing OSP Offshore Safety Permit P&ID Piping and Instrumentation Diagram PAUT Phased Array Ultrasound Testing PEC Pulsed Eddy Current PFD Process Flow Diagram PIMS Pipeline Integrity Management System PO Purchase Order PR Purchase Requisition R&D Research and Development RFQ Request for Quotation RVI Remote Visual Inspection ix and QMS Quality Management System QA/QC Quality Assurance and Quality Control SE Service Entry SIWES Student Industrial Work Experience Scheme SNI Sensor Networks Inc. SO Service Order UT Ultrasound Testing x CHAPTER ONE 1.0 INTRODUCTION 1.1 INTRODUCTION TO THE SIWES TRAINING PROGRAM 1.1.1 OVERVIEW The Student Industrial Work Experience Scheme (SIWES), also known as Industrial Training is a compulsory skills training programme designed to expose and prepare students of Nigerian Universities, Polytechnics, Colleges of Education, Colleges of Technology and Colleges of Agriculture, for the industrial work situation they’re 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 institution. SIWES was established by ITF (Industrial Training Funds) in the year 1973 to solve the problem of lack of adequate proper skills for employment of tertiary institution graduates by Nigerian Industries. The Students’ Industrial Work Experience Scheme (SIWES) was founded to be a skill training program to help expose and prepare students of universities, polytechnics and colleges of education for the industrial work situation to be met after graduation. This scheme serves as a smooth transition from the classroom to the world of work and further helps in the application of knowledge. The scheme provides students with the opportunity of acquainting and exposing themselves to the experience required in handling and managing of equipment and machinery that are usually not made available in their institutions. 1.1.2 OBJECTIVES OF SIWES SIWES is a key factor required to inject and help keep alive industrialization and economic development in the nation through the introduction and practical teaching of scientific and technological skills to students. (Culled from Detailed Manual on SIWES Guidelines and Operations for Tertiary Institutions). Objectives of the Students Industrial Work Experience Scheme include: 1. Provide an avenue for students to acquire industrial skills for experience during their course of study 2. Expose students to work methods and techniques that may not be available during their course of study. 1 3. Bridging the gap between theory and practice by providing a platform to apply knowledge learnt in school to real work situations 4. Enabling the easier and smoother transition from school by equipping students with better contact for future work placement 5. Introduce students to real work atmosphere so that they know what they would most likely meet once they graduate. 1.2 ORGANIZATION HISTORY Fortis Engineering Services Limited is an ISO 19001;2015 certified indigenous oil and gas servicing Company established in March 2018 with Head Office in Oniru-Lekki, Lagos and Operational base in Port Harcourt. The company is a fully owned Nigerian oil and gas servicing company. Their primary focus is to employ competent personnel and utilize specialized, technical expertise to positively contribute to the Nigerian Petroleum and Energy industry. They seek to constantly deploy highly effective technologies through creative, customeradapted solutions and their aim is to provide unrivalled problem-solving proficiencies within the industry. 1.2.1 MISSION STATEMENT Innovative use of technologies to deliver client-focused value through the improvement of assets at all stages of its lifecycle. 1.2.2 VISION STATEMENT To be recognized as the best-in-class Asset Integrity and Maintenance (AIM) Reliability Solutions in the Nigerian Oil & Gas Industry providing Engineering, Procurement, and Operations services with proactive regards to environment, health & safety while enhancing local capacity building in line with the Nigerian Content Development policy. 2 1.2.3 VALUE SYSTEM The Organization’s Value System is built on the 3Cs and 3Ts as shown below. Fig 1.1 Fortis Value System 1.2.4 KEY SERVICES The Organizations’ key services are focused on the following core areas; I. Key Areas • Operations & Maintenance. • Asset Integrity Management. • Equipment & Maintenance. • Procurement. II. Training and Certification. III. Inspection Services • Non-destructive testing (NDT) • Vessel Inspection/Certification • Valve Inspection & Servicing • Piping inspection Services IV. Crane, Davits & Rope Access 3 V. Rotating Machinery • Condition Monitoring Service 1.3 ORGANIZATION STRUCTURE 1.3.1 I. DEPARTMENTS TECHNICAL/ENGINEERING: The department is tasked with handling all Engineering, Procurement, Installation and Commissioning/Construction (EPIC) related works such as; Equipment maintenance, Asset integrity, Procurement and Inspection Services. This was my main department of assignment and I liaised closely with my supervisor to undertake these projects effectively. II. RESEARCH AND DEVELOPMENT: To always ensure a competitive advantage for the organization as well as impact positively in the technological advancement of the Nigerian oil and gas industry, the Research and Development Department was put in place to scout for international partnerships with companies producing novel technologies that can be utilised in solving some of the challenges faced in the oil and gas industry, III. QUALITY MANAGEMENT AND QUALITY CONTROL: As an ISO 9001:2015 certified Organization, the QM/QC department ensures that all procedures/processes used by the organization conforms with the laid-out standards put in place by the relevant authorities. In the instance where a process is non-conforming, the QM/QC department is charged with performing a root cause analysis to determine the root cause and also employ a corrective action in resolving the non-conformance. IV. ADMINISTRATIVE: The Administrative department of the organization liaise closely with the other 3 departments to ensure that all documents relevant to the successful operation of the company and its projects are well accounted for using an effective filing structure. 4 1.3.2 COMPANY ORGANOGRAM Fig 1.2 Fortis Organogram 1.4 INTERN’S ROLES/RESPONSIBILITIES AND ACTIVITES My internship period at Fortis Engineering Services Limited was for a period of 6 months (May 24th 2021 to November 9th 2021), I was assigned to the Technical/Engineering department under the supervision of Engineer Oamen Aletor (Engineer Operations), I also interned concurrently in the Research and Development Department, Quality Management and Quality Control Department as well as the Administrative Department The key focus of the internship was to undergo a 5 agenda training plan that was put in place by the Organization to ensure that all interns are exposed to the key areas of operations in the industry while getting hands on experience. The Training Plan comprises of; 5 I. Research and Development, II. Technical Presentation Development, III. Field Experience, IV. Technical Report Writing and V. Bid Preparation I resumed by 8am and closed by 5pm on a daily basis, while undergoing the training plan I was tasked with liaising closely with my supervisor, the Head of Technical operations and other interns to carry out Engineering, Procurement, Installation and Construction Projects. 6 CHAPTER TWO DETAILS OF WORK DONE DURING INDUSTRIAL TRAINING 2.1 THE TRAINING PROGRAM It is mandatory for every new intern to undergo an intensive 5 agenda training plan that runs concurrently during their internship period at Fortis Engineering Services Limited, the training plan is in line with the major activities of the company and their key area of specialization, the aim of the training plan is to ensure that the interns fully understand the operations of oil and gas servicing companies in the country as well as to build capacity and ensure employability of the interns upon graduation. I was assigned to the Technical/Engineering Department and the training plan was streamlined to ensure relevance to my course of study. 2.2 RESEARCH AND DEVELOPMENT Research and Development (R&D) is a process intended to create new or improved technology that can provide a competitive advantage at the business, industry, or national level. The goal is typically to take new products and services to market and add to the company's bottom line. Some key advantages of R&D include; I. Unique selling point - R&D can help you develop unique products and services. II. Income - unique products and services resulting from successful R&D projects can generate new or enhanced income streams, but R&D can also attract potential new investors/partners to your business. III. Funding - for businesses to seek public-sector innovation, research and development grants or even EU funding for innovation. IV. Tax relief - you can claim R&D tax relief to reduce your company's tax bill V. Competitive edge VI. Collaboration - It allows for the transfer of skills and knowledge, and access to facilities, expertise and potentially new ideas that would otherwise be out of reach of your business. VII. Reputation - engaging in R&D can help you strengthen your brand and reputation. If you're collaborating with a trusted, reputable partner or a strong scientific institution, the commercial success of resulting products and services can benefit from their involvement. 7 The Basic R&D structure utilized by Fortis Engineering is show in the flow chart below. Fig 2.1 Fortis Research and Development Framework. During the period of my internship, I worked closely with my supervisor to scout for new technologies that can be of economical benefit to the company. The process starts by first identifying a problem or opportunity within the oil and gas industry, this ranges from Equipment maintenance problems, pipeline integrity management like corrosion, pigging and bunkering. After identification of a problem or an opportunity in the market, we proceed to scout for novel technologies that meets the requirements for solving such problems A R&D compilation spreadsheet is created where we store all the potential technologies discovered in the team scouting session, at the Bi weekly R&D meeting which holds on Thursdays with the entire Management in attendance, the novel technologies are presented to the Management for scrutiny and critic, if the technology is satisfactory, we deploy a set of SMART actions which includes further research on the technology and also initiate contact with the foreign company with the aim of having an inquiry meeting to further understand the capabilities of the technology and subsequently to discuss possible partnerships so as to make available these new technologies to the Nigerian oil and gas industry. 8 Some notable novel technologies discovered by the R&D team and is being currently being deployed in the industry or undergoing possible partnership meetings are discussed below. I. SENSOR NETWORKS SMARTPIMS, MICROPIMS AND WEBPIMS ULTRASOUND CORROSION MONITORING SYSTEM Infrequent and unreliable inspections could result in corrosion-related failure events leading to production shutdown, asset damage, environmental pollution, and reputation damage. Possible metal loss and pipe-wall degradation in pipelines, flowlines, risers, bends, pressure vessels, tanks, etc., emerge due to erosion and corrosion at critical areas. Pipeline explosions resulting from such events have the potential of resulting in a fatality and enormous reputation damage. Hence the need to replace wasteful, infrequent, vulnerable Asset Management methods with real-time, non-intrusive, reliable, Automated and Proactive Technology. The SNI SmartPIMS, MicroPIMS and WebPIMS ultrasound corrosion monitoring system is a cost-effective way of ensuring asset integrity in critical parts and eliminated the need for routine and manual nondestructive testing that are prone to false readings. We engaged Sensor Networks for a partnership which allowed us become the sole distributor and installer of the SNI products in Nigeria and Africa at large. So far, we have procured and installed these devices in the facilities of many International and Local oil companies including; Shell Nigeria, Seplat Petroleum, Chevron Nigeria, Ambatovy-Madagascar etc. Fig:2.2 SNI Services Triangle Chart. 9 Fig. 2.3 SNI SmartPIMS Pipeline installation demonstration. II. NOVOSOUND KELPIE The Kelpie represents a breakthrough in ultrasonic inspection, the Kelpie’s unique flexibility and low-profile form (0.5mm) allows it to flex, twist and bend during scanning, conforming to difficult shapes and surfaces. Designed for detecting flaws such as cracks and voids in metals and composites, the Kelpie can wrap around smalldiameter piping, scan uneven surfaces and bend round elbow joints with unparalleled precision and accuracy. With enhanced surface conformance, the Kelpie is a marketleading tool for corrosion mapping of critical assets – achieving increased scan speed and enhanced imaging. This novel and innovative technology is critical in easy corrosion mapping of pipelines of various diameters to determine flaws like cracks, pores and pitting. discovered by the Research and Development Department of the company, the is technology is under discussion by both companies for its deployment in Nigeria. 10 Fig 2.4a Fig 2.4b Fig 2.4a/b Novosound Kelpie Toolbox and Test Demonstration. III. TFT PNEUMATICS NON-SPARK GRINDING/COATING REMOVAL TOOL We were awarded a contract to install SNI smartPIMS on a client’s flowline, the flowline environment was however explosion rated and we needed to decoat and prepare the surface of the flowlines prior to installation of the smartPIMS, no form of spark tool is allowed in an explosion rated environment as this could lead to a fire hazard, hence, the need to source for an unconventional non-spark, coating removal tool for this application. Our research led to the discovery of the TFT pneumatic nonspark grinding tool. TFT pneumatics are the suppliers of the only surface preparatory, grinding, and cutting tools certified by DNV for use in potentially explosive and hazardous atmospheres. They are Classified as Cold work tools and are safe to use in Offshore Platforms, Refineries, Chemical Plants, Mines, FPSO’s, ships, and many other places where hydrocarbons are present. These tools are commonly referred to as sparkless grinders and are ideal for use where other non-sparking tools are used. The tools do not require Hot Work Permits and are also certified for Dust Explosive atmospheres. 11 Fig 2.5a Fig 2.5b Fig 2.5a/b ATEX rated pneumatic grinder toolbox and demonstration 2.3 TECHNICAL PRESENTATION Aside from the technical know-how that every engineer must possess, it is important that they are able to communicate clearly their ideas to potential clients and investors without being misunderstood. The Technical Presentation plan ensured that I developed strong communication skills, always being as descriptive as possible to ensure my ideas are understood. During my internship period, I was tasked with taking minutes and the weekly departmental meetings as well as to anchor the bi weekly Research and Development Meeting, Business Development meeting and dialogue with clients/partners during synchronization or inquiry meetings between Fortis Engineering and a third-party company. I also developed and made technical presentation on the following subjects; I. INTERNSHIP REPORT EXPERIENCE PRESENTATION It is mandatory for all interns who undertook the 5 agenda training plan to develop and make a power point presentation of their experience to the management. At the end of my internship, I followed suite to make two presentations, summarily explaining all I have learnt with regards to the training plan during the period of my attachment to the company 12 II. FORTIS POWER BUSINESS OPTIMIZATION ANALYSIS PRESENTATION In the 5th month of my internship, I alongside the Head of Technical Operations performed a business optimization analysis on Fortis Power, which is basically a feasibility study to determine the profitability of the subsidiary. The BOA was performed by determining the Capital Expenditure (CAPEX) by summing the nonrecurring cost of starting up the subsidiary and the Operational Expenditure (OPEX) for different Annual Maintenance Contracts based on the sizes of the generators to be serviced for a period of two years (2020 and 2021). This cost was then compared to the net profit for these years to determine how profitable the subsidiary has been, based on our results, a profit target was agreed upon for the year 2022 and this profit target was used to develop a new price list for the different Annual Maintenance Contract (AMC) of our Clients. Upon conclusion of the BOA and successful collation of the necessary data, I developed a PowerPoint slide detailing the result of our analysis and making relevant recommendations. III. A PRESENTATION ON FES POLICIES AND PROCEDURES. Upon commencement of internship at the company, all interns are required to thoroughly read the company’s Handbook containing all the policies and procedures guiding the rules of engagement within the organization. After a successful completion of the first 5 weeks as an intern I made a power point presentation on the policies and procedures of the company, summarily explaining the key areas of the handbook and making recommendations on what can be done better. IV. ENGINEERING ENTREPRENEURSHIP IN NIGERIA Starting up an engineering business is no easy task as there are many factors that come to play in satisfying certain requirements in order to effectively operate in the business world. The Head of Technical Operations organized a workshop on how to successfully run an engineering business in the country, as such, he enlisted my help in developing a power point presentation clearly explaining the challenges of engineering enterprise in Nigeria, SWOT analysis for a successful engineering business, business regulatory requirements as well as financial statutory requirements. V. 21ST CENTURY ENGINEERS. All interns being considered for placement in the company are required to make a presentation on the 21st century Engineer to the HTO who then evaluates the performance of the intern and draft out a personalized training plan. 13 2.4 FIELD EXPERIENCE The most important agenda of the training plan was acquiring relevant field experience, as the real-life application of the technologies being deployed while executing a project gives a full us a full understanding of its operations. In the duration of my internship, I was opportune to acquire hands on experience in deploying some of the technologies used in executing services. Majority of the field experience obtained were in line with deploying Non-Destructive Testing Technologies which includes; I. SENSOR NETWORKS SMARTPIMS/MICROPIMS AND WEBPIMS The SNI SmartPIMS is a cost effective, reliable and accurate NDT technique for the continuous monitoring of critical assets like flowlines, tankers, reservoirs, and vessels against pitting and erosion corrosion. It operates on the principles of ultrasonic waves to repeatedly measure the thickness of the surface on which it is installed on and use this data to compute weight loss and corrosion rate at that spot in m/yr. The SmartPIMS system is comprised of ultrasonic transducers that serves as the probe, connecting cables, and a Modbus. The Modbus tablet systems address buried pipe and mobile assets (tanker cars and trailers) that require accurate, repeatable, infrequent measurements. Modbus control room systems are ideal for offshore platforms when wired directly into the asset’s plant control system or CDS. The installed sensors provide automatic closed-loop monitoring of the production process. The data derived from the Modbus can be analyzed graphically using SNI cloud data analysis software called the WebPIMS. Fig 2.6 SNI smartPIMS system configuration 14 I participated in a series of SNI smartPIMS installation Demostration, field deployment as well as data collection and analysis using the webPIMS for some of our clients that needed their critical assets monitored. Fig 2.7 On-site installation of SNI SmartPIMS Fig 2.8 Corrosion data reading using SNI WebPIMS 15 II. PHASED ARRAY ULTRASOUND TESTING The ultrasonic Phased Array instrument is a multi-orientated Phased Array (PA) inspection or Equivalent pulse echo type and is equipped with a calibrated dB gain or attenuation control stepped in increments of 1dB or less. The system is capable of generating and displaying linear scan & Sectorial scan images, which can be stored and recalled for subsequent review. The instrument is also capable of operation at frequencies over the range of 1 MHz to 27 MHz. The Phased Array system provides a variety of analysis capabilities including A-scan display and parameter readout associated with software UT studio Software which can be used for the post analysis. During my internship Period, we performed wall thickness measurements on a 12,000 litres capacity diesel tank under construction using PAUT to verify that all sections of the steel sheet used for the construction was 12mm. We commenced activities by carrying out visual inspection on the tank and identification of critical exposed sections to be tested. After successfully verifying the thickness of the tank using PAUT we proceeded with coating and calibration processes. Fig 2.9 PAUT Hydroform, Olympus Scanner and Diesel Tank 16 The data is provided based on color mapping. The mapping (C-Scan) is assigned to show the signals in Blue, Green, Yellow and Red, representing varying thickness between 0.05 – 12mm. The white shaded strip in the C-scan image is due to uneven surface, obstructions. The images might be magnified in the proprietary software for analysis to give better visualization for sizing. As with ultrasonic thickness measurements, the presence of plate laminations, rust, coating can create false images of wall thickness and corrosion. Corrosion mapping cannot be done 100% on inaccessible areas such as welded surroundings, curvatures, nozzles and its surrounding and support structures (e.g., support plates, platforms, etc.). Here manual UT can be used to give indication of any material loss in selected areas Fig 2.10 Typical wall thickness color chart/code using PAUT III. PULSED EDDY CURRENT Fortis team of Inspectors conducted Pulsed Eddy Current Array advanced nondestructive testing on polyethylene coated flowlines Agbada Flow station using the PECT (Pulsed Eddy Current Testing) technology with the final data acquisition being completed on 30/05/2021. The PEC system exists out of the following main parts: 17 • A probe and cable suitable for the wall thickness of the object and distance from probe to object. • An Eddyfi Lyft PEC instrument, including pulsing electronics, batteries and a computer for processing, displaying and storage of measurement results. • Mass data storage unit. Pulsed Eddy Current (PEC) is an inspection technique for inspecting carbon steel objects such as pipes and Pipelines, without the need for contact with the steel surface. PEC can measure percentage variations in steel thickness through any non-conductive a non-magnetic material between sensor and steel surface such as air, insulation material, concrete, plastics, coatings, paint, sea water, marine growth, deposits, oil, Fireproofing, Composite wraps, scab corrosion product etc. Fig 2.11 Dig up and NDT testing of flowlines using PEC IV. BORESCOPE REMOTE VISUAL INSPECTION (RVI) Remote Visual Inspection or Remote Digital Video Inspection, also known as RVI or RDVI, is a form of visual inspection which uses visual aids including video technology to allow an inspector to look at objects and materials from a distance because the objects are inaccessible or are in dangerous environments. RVI is also a specialty branch of non-destructive testing (NDT). 18 Fortis team of inspectors performed NDT inspection at the Okoloma gas plant. The purpose of the inspection was to serve as a predictive/regulatory scheduled maintenance tool to assess the "health" and operability of the Air Cooler & Heat Exchanger at the Gas Plant. RVI enables greater inspection coverage, inspection repeatability and data comparison. Teslong NTS300 equipment was deployed to carry out the inspection. Fig 2.12 RVI of Heat Exchanger tubes using Borescope This report covers the inspection of inside surface areas of the entire tube length of the Heat Exchangers and fin fan coolers, usually inaccessible to the eye without disassembling surrounding structures and machinery. It has allowed for the assessment of hidden discontinuities which may cause major problems, e.g., poor welding, surface defects, dents, crack, corrosion pits, general condition, degradation, blockages and foreign materials. Fig 2.13 images from the Heat Exchanger Tubes using Borescope RVI 19 2.5 TECHNICAL REPORT WRITING One of the main forms of communication in engineering is the technical report. In the workplace, the report is a practical working document written by engineers for clients, managers, and other engineers. A technical report is a formal report designed to convey technical information in a clear and easily accessible format. It is divided into sections which allow different readers to access different levels of information. While reports vary in purpose and in the type of information they present (e.g., site visits, environmental impact or assessments, industrial projects, investigative studies, or design projects), all are based on a similar structure and follow similar presentation conventions. I. TITLE PAGE This page gives: • The title of the report • The authors' names and student IDs • The course name and code, the department, and university • The date of submission. The title of the report should indicate exactly what the report is about. The reader should know not only the general topic, but also the specific aspect of the topic addressed in the report II. ABSTRACT/EXECUTIVE SUMMARY The Abstract is usually written last of all. It provides a brief overview of the substance of the report. It is a stand-alone document generally used by busy managers who might not have time to read the full report. That’s why it is usually referred to as the Executive Summary in the workplace. The abstract is not an introduction to the topic. It should focus on what you did, how you did it, and the main outcomes and significance of your work. The Abstracts: • States the topic of the report • Briefly outlines your approach to the task (if applicable) • Focuses on the results or outcome of the project, the findings of your investigation: or the key aspects of your design • States the significance or implications of the results. 20 III. TABLE OF CONTENTS The Contents page sets out the sections and subsections of the report and their corresponding page numbers. It should clearly show the structural relationship between the sections and subsections. A reader looking for specific information should be able to locate the appropriate section easily from the table of contents. Sections are numbered using the decimal point system. Section numbers appear on the left margin, page numbers on the right. IV. INTRODUCTION The Introduction tells the reader what the report is about. It sets the project in its wider context, and provides the background information the reader needs to understand the report. The Introduction: • Introduces the topic of the report in context • Explains the problem and/or motivation for the project • States the aim/s of the project • Indicates the purpose of the report • Briefly outlines the report structure (not necessary in a short report). In a short report, the technical background necessary to understand the problem may be included in the Introduction. In longer reports this may be summarized in the Introduction and presented in detail in a separate section. V. BODY OF THE REPORT The Introduction and Conclusions act as a frame for the body of the report, which is where you present your own work. The information should be organized so that the reader can follow the development of your project. You will therefore need to put some thought into ordering the sections and choosing concise but informative headings and subheadings. The body of the report: • Presents the information from your research, both real world and theoretical, or your design • Organizes information logically under appropriate headings • Conveys information in the most effective way for communication by means of: 21 • Figures and tables • Bulleted or numbered lists • Formatting to break up large slabs of text. VI. CONCLUSIONS AND RECOMMENDATIONS The Conclusions and Recommendations may be combined or, in long reports, presented in separate sections. If there are no recommendations to be made as a result of the project, just call this section Conclusions. The Conclusions section sums up the key points of your discussion, the essential features of your design, or the significant outcomes of your investigation. As its function is to round off the story of your project, it should: • Be written to relate directly to the aims of the project as stated in the Introduction • Indicate the extent to which the aims have been achieved • Summaries the key findings, outcomes or information in your report • Acknowledge limitations and make recommendations for future work (where applicable) • Highlight the significance or usefulness of your work. • The conclusions should relate to the aims of the work: VII. REFERENCES AND APPENDICES All information, methods, data, diagrams and maps, whether obtained or based on the work of others, must be acknowledged by using the correct or recommended reference style. Appendices contain material that is too detailed to include in the main report, such as long mathematical derivations or calculations, detailed technical drawings, or tables of raw data. The content should be summarized and referred to at the appropriate point in the body of the report. The conventions for appendices are as follows: • Each appendix must be labelled with a number (or letter) and title • The appendix numbers and titles must be listed on the Contents page under the Heading Appendices (if more than one) or Appendix (if only one) • Each appendix must be referred to by number (or letter) at the relevant point in the text. 22 upon completion of every service order, it is mandatory that we develop a technical report that gives in detail the work done, results obtained as well as make recommendations based on the results. The developed result is then submitted to the client for review and subsequent corrections/reviews are made to to report until it is deemed satisfactory. I was opportune to participate in the development of two technical reports after successful completion of internal rotary inspection system (IRIS) and Borescope inspection nondestructive testing services 2.6 BID PREPARATION A majority of the revenue gotten by oil and gas servicing companies are from EPIC projects (procurement or services) that are competitively bided for. Due to the high profit yields of these kind of project, a lot of work goes into the preparation of a very competitive bid to be submitted to the company. As earlier stated, the projects being bided for can be broadly grouped into two; Procurement Projects and Services Project. I. PROCUREMENT BID: Most international/local oil companies require scheduled maintenance or repairs of their critical assets, other times they are working on expanding their production capacity by building new assets like factories, substations, flowlines etc. To achieve thus, they need to purchase critical spares like pipes, flanges, elbows, rope access kits, NDT equipment’s, specialized machineries and tools. The regulations in the country does not permit these companies to make such purchases directly from the Original Equipment Manufacturer, hence they have to go through a third-party oil and gas servicing company for their Procurements. The entire Procurement bidding process is explained below; • INITIATION OF CONTACT: in this stage, the client reaches out to participating companies who wish to bid competitively for the project, this is usually done by sending emails containing instructions on how to undertake the bidding process to all the participating companies registered in the client's database. The most effect way of initiating contact however is through the use of third-party online bidding platforms such as NIPEX, SHELL ARIBA, SEPLAT E-TENDER platform etc. The client. Uploads all the required files required for a successful bid submission and all companies registered in the database of this bidding platforms are able to view the Request for Quotation 23 (RFQ) and can either decide to participate in the process or not. The online bidding process ensures transparency and fairness so that all participating companies have an equal chance of winning the contract. All RFQs come in either a single envelope or double envelop format, for the single envelope, the technical competency of the participating companies is evaluated separately which is then followed by a commercial evaluation at a later time. For a double envelope RFQ, both the technical and commercial competence are evaluated together. • TECHNICAL EVALUATION: Most RFQs are accompanied with some technical criteria the participating company must meet before being considered for the contract. The technical requirements usually cover the following key areas; Company details, Organization structure, Lens and claims, Key personnel, Project experience, Quality management system, Health, safety and environment, Nigerian content development plan A submission of all the technical requirements is made using tender documents containing details peculiar to the project, the client evaluates all the technical submissions based on a set benchmark and all those who beat this benchmark move to the commercial evaluation stage. • COMMERCIAL EVALUATION: All participating company that successfully passed the technical evaluation stage are invited to submit a Quotation based on the RFQ sent by the clients. The Quotation is usually gotten when the participating companies engage the OEMs of the required products. The client makes a final selection based on the most competitive price i.e., this is usually but not necessarily the cheapest Quotation. The procurement team of the client further engages the selected company for discounts and a possible Contract. If satisfactory, a Purchase Requisition (PR) is generated internal by the client and this marks the end of the bidding process and the beginning of the project execution stage. • CONTRACT/PURCHASE ORDER After a successful deliberation between the client’s procurement team and the selected company and the generation of a PR, a Contract is issued to the selected 24 company which has the lump sum of the project to be executed. As the client deems fit, Purchase Orders are called out from the Contract which is an approval from the client to proceed with the procurement of the said materials listed in the PO. • GOOD RECEIPT NOTE The selected company then engages with the OEM for the procurement of the materials based on an agreed INCO TERM, upon successful shipment and delivery of the products to the client, a good receipt note (GMR) is issued to the company which is attached to the PO and used un generating the invoice sent to the client for payment. II. SERVICES BID Some of the largest revenues are from service contracts that are competitively bided for, the services rendered could be; • Non-Destructive Testing services such as Phased Array Ultrasound Testing (PAUT), Pulsed Eddy Current (PEC), Borescope Remote visual inspection and internal rotary inspection system. • Engineering, Procurement, Installation and Commissioning Services such as the construction of flowlines or bulkline manifolds. • Recertification of equipment The steps involved in bidding for Service Contracts are the same with that for Procurement contract with some few deviations/additions after a Contract/PO has been issued. • EXECUTION OF THE PO Upon successful receipt of the PO the selected company is mobilized on site to carryout the project scope present in the PO. After completion of the scope of work the company is demobilized. • TECHNICAL REPORT SUBMISSION AND REVIEW Every completed service contact must be accompanied by a technical report submitted to the client, the technical report contains details on the work done, the results obtained and recommendations based on these results. The report is reviewed by the client and subsequently revised by the company until a final and satisfactory Technical Report revision is obtained. 25 • SERVICE ENTRY Once the Technical Report is submitted and deemed satisfactory, a Service Entry (SE) is issued to the company which is attached to the PO for generating the invoice for payment. Fig 2.14 Engineering Bidding Process listed below are all the Bids I participated in during my internship at Fortis Engineering Services Limited. I. Procurement Of 6 Inches Line Pipes for Seplat's Western Asset Operations II. Provision Of Flowline and Pipeline Construction Services in Oml 18 III. Engineering, Procurement, Construction, Installation and Commissioning Of 5km X 4 Flowlines IV. Provision Of Flowline, Delivery Lines and onplot Piping Inspection V. Expression Of Interest for Ultrasonic Testing of Pressure Vessel in OML30. VI. Expression Of Interest for Recertification of Lifting Equipment in OML30. VII. Provision Of Road Resurfacing and Repairs at CNL Lekki Estate and Office Complex VIII. Construction Of Bulklines/Manifolds & Gas Pipelines (Call-Off) For Western Assets – OMLS 4, 38 & 41 Locations. IX. UAR18082021 Pipes Fittings Flanges and Ropes 26 X. Shell Procurement {Flanges, Gasket and Pipelines) -UAR10062021dw XI. Provision Of Valve Servicing/Repairs Services for Manual Valves and Control Valves - Seplat/Lag/ITT/2019/Pd/117091 XII. Shell Procurement of Pipelines, Valves and Flanges – Quotation Number SAN19032021a XIII. UAR18082021 Pipes Fittings Flanges and Ropes 2.7 OTHER RELEVANT EXPERIENCE GAINED Aside from the 5 agenda training plan, I was also engaged in a series of workshops, trainings and short courses that also contributed to the overall experience acquired during the course of my internship. Some of these engagements include; I. Interpretation of Piping and Instrumentation Diagram (P&ID) as well al Process Flow Diagrams (PFD) II. Introduction to Engineering Supply Chain Management using the Opportunity Vessel Tracker and Envelope Vessel Tracker models. III. \Workshop on Quality Management System detailing the process of performing Root Cause analysis in resolving Non-Conformances. IV. Workshop on Basic Offshore Safety Induction and Emergency Training. V. Workshop on the operations of the offshore oil and gas industry including the operations of Floating Production Storage and Offloading Vessels. VI. Personal development course on the use of Microsoft Excel, Microsoft PowerBI and SQL. 27 CHAPTER THREE DISCUSSION, ANALYSIS AND EVALUATION 3.1 PROFESSIONAL KNOWLEDGE AND COMPETENCE GAINED The major aim of the SIWES program is to avail students in tertiary institutions opportunity to bridge the gap between the academia and the industry/labour market through intensive trainings during the course of the program to acquire skills and experience relevant to their field of study thus making them employable post-graduation. Metallurgical Engineering deals with metals. It is a discipline that focus on the production of metals, metallic parts by utilizing the properties of these materials. The interdisciplinary field of Materials Science, also commonly termed as Materials Science and Engineering, is the design and discovery of new materials, particularly solids. Materials Science still incorporates elements of physics, chemistry, and engineering. The 6 months internship experience made me understand the need for proper work ethics through professional dressing and cordial relationship between employees and employers, the induction process at the beginning helped me fully understand organizational structure and hierarchy in the work place. Finally, I gained the following experience relevant to my courses of study; I. MATERIAL LABORATORY II (MME 417) The course elaborates on the different types of NDT techniques employed in engineering. A major part of my field experience dwelled on the use of these NDT techniques including Ultrasound Testing, Pulsed Eddy Current and Visual Inspection as a form of predictive maintenance for examining and monitoring critical assets against failure. II. ELECTROCHEMISTRY AND CORROSION (MME 412) As stated in the course, a majority of the asset failures in the oil and gas industry are as a result of corrosion, most especially pitting and erosion corrosion, clients utilize the different NDT tests mentioned above to predict against catastrophic failures of their assets due to corrosion. The internship experience availed me the opportunity to fully understand the extent of damage caused by corrosion in the industry, their forms, how to identify them and mitigating methods used curtailing their effects. 28 III. TECHNICAL COMMUNICATION (GEG 411) Engineers are required to be able to effectively communicate problems, research and solutions to their clients as taught in the course. During my internship, I consolidated the technical reporting skills acquired in school by actively participating in preparing Technical Reports for Services rendered, Technical Presentations for clients and in house meetings as well as anchoring multiple synchronization meeting between Fortis and other Organizations. IV. ENTREPRENUERSHIP FOR MATERIALS ENGINEERS (MME415) The knowledge on Engineering Supply Chain Management in rendering procurement services for oil and gas companies, Quality management system in ensuring maximum customer satisfaction and efficiency in the company’s processes, the entire process of Engineering Bid preparation as well as workshops on the requirements for setting up an engineering business in Nigeria are in line with what was taught in the course. V. WELDING AND FABRICATION (MME 326) I participated in the fabrication/weld inspection of two 12,000 liters capacity diesel tank through visual examination and a subsequent weld assessment using Phased Array Ultrasound Testing. This experience consolidated my knowledge on the types of welding and welding defects to look out for in the constriction of pressure bearing structures like the diesel tank. VI. PROPERTIES OF MATERIALS (MME 324) Many of the NDT services conducted on assets like flowlines and gas stations requires for us to completely understand the properties of the materials to be tested so as to know the specific requirements for the test such as the required surface preparation, coating requirement post test as well as the nature of the test to be conducted VII. The training experience will also ensure that I fully comprehend the 500 level courses I will be taking this session like ENGINEERING ECONOMICS, MANAGEMENT FOR ENGINEERS and INTRODUCTION TO ENGINEERING CONTRACT. 29 3.2DESCRIPTION OF TOOLS AND EQUIPMENT USED I. SNI SMARTPIMS The smartPIMS is a non-intrusive ultrasound corrosion monitoring device that operates by using a UT probe to take periodic thickness readings of low spots on which they are placed on. These wall thickness readings are collected by a Modbus and analyzed over time to obtain the wall thickness loss and corrosion data in m/yr. Fig 3.1 SNI smartPIMS in house installation Demonstration II. ATEX/EX RATED PNEUMATIC GRINDING TOOL One of the smartPIMS installation service was to be carried out in an ATEX/EX environment as such, non-spark tools were required for the decoating/surface preparation of the flowlines. We purchased an ATEX rated pneumatic grinding tool made from a special composite of Tungsten Carbide, the tool has the ability to remove coatings like paint, tar and composite wraps from the surface of the flowline without causing spark or emitting heat. 30 Fig 3.2 ATEX rated Pneumatic grinding and coating removal tool. III. HYDROFORM PHASED ARRAY SCANNER The HydroForm Scanner consists of a specially designed carriage for inspecting pipes, tanks and vessels using immersion technique. The measurements ascertain thickness which is a function of probe positioning for the area scanned, and may be provided in pure numerical form or as color coded maps. IV. OLYMPUS OMNISCAN MX2 The Olympus OmniScan MX2 flaw detector is a complete phased array toolbox. Powerful tools, like total focusing method (TFM) images and advanced visualization capabilities, enable the inspector to complete your inspection with greater confidence. The OmniScan flaw detectors provide powerful inspection capabilities for manual and automated applications. They can be used with a full range of probes, scanners, and accessories, V. BORESCOPE PROBES The Teslong NTS300 is a model of a borescope probe which is used in the remote visual inspection of opening and holes that cannot be inspected with the eyes or other techniques. It is comprised of a rotatory camera mounted on a flexible pole that is inserted into the opening to be viewed. The imaging/video recording of the viewed section is then displaced on a handheld screen. 31 Fig 3.3 Teslong NTS300 Borescope VI. HANDHELD ULTRASOUND GAUAGE The handheld ultrasound gauge is a wall thickness gauge that is used to verify the nominal thickness of pipelines or sections that are to be monitored using the smartPIMS. The gauge is usually first calibrated using a circular steel block of known thickness and water as the means of propagation of the ultrasound wave. Fig 3.4 Hnadheld Ultrasound Wall Thickness Gauge 3.3PROBLEMS ENCOUNTERED My internship at Fortis Engineering Services Limited over the past 6 months has been a worthwhile experience as I gained practical knowledge relevant to the labour market. The 32 duration of my internship was however riddled with some challenges that if properly looked into will ensure a more fulfilling experience. I. INABILITY TO SECURE A PLACEMENT: Due to the prevailing Corona Virus Pandemic, securing an internship placement when due was very challenging as most public and private organizations were no longer recruiting due to fears of contacting the virus and government regulations that were put in place to curtail the spread of the virus. After a rather exhausting search around Lagos state, I was able to secure a placement 2 weeks after the official start date of the internship program after reaching out to an i alumnus of the department. II. INADEQUATE RENUMERATION: While the purpose of the internship was not to be well compensated for our learnings, one has to be financially stable to cover for their transport and feeding expenses during the duration of the training. The company was benevolent enough to provide a monthly stipend, the stipend was however not sufficient and during the 6 months I had to live on a tight budget. III. DAILY COMMUTING DISTANCE: Fortis Engineering is located in Lekki, due to the inability to secure accommodation on the island for easy commuting, I had to stay on the mainland and commuted an average of 44km on every working day. Coupled with the incessant traffic in Lagos State and the on-going road repairs the commuting experience was a bad one. I requested for an earlier closing time which helped me drastically beat the traffic. IV. UNAVAILABILITY OF EQUIPMENTS: Due to the fact that Fortis Engineering Services Limited is predominantly an Engineering supply chain management/Research and Development Organization coupled with the that most NDT services on clients’ assets requires special permits like BOSIET, OSP and COMPEX, the equipment used were therefore not readily accessible to interns. We had a lot of in-house demonstration on some of the tools and equipment being deployed on the field, this assisted me in better understanding the processes in conduction some of these works. 33 CHAPTER FOUR CONCLUSION, LIMITATIONS AND RECOMMENDATIONS 4.1CONCLUSION The SIWES program is a very good initiative by the Federal Government aimed at bridging the gap between academic learning and industrial experience. This was fully achieved in my 6 months internship training at Fortis Engineering, while it had its shortcomings, I was able to gain vital experience relevant to my course of study. Over the duration of the internship, I gained experience on the operations of oil and gas servicing companies which includes but are not limited to, Equipment Maintenance, Asset integrity, Quality Management System as well as Engineering supply chain management. In addition, the internship program has greatly influenced my oral and written communication skills through exposure to numerous opportunities in technical report writing as well as presentations 4.2LIMITATIONS While my internship role does not avail me access to numerous tools and equipment because most of the equipment are deployed on sites that I do not have sufficient clearance to be present in those environments (COMPEX, OSP, BOSIET etc.,). I had some difficulties in navigating the operations of some of the equipment like the SNI smartPIMS, ATEX rated pneumatic grinding machine and PAUT system due to their complexities, functionalities and being required to be operated by specialized/skilled operators. However, after sufficient in-house demonstrations between my supervisor and the interns on the operation of these tools, I was able to easily navigate my way through. 4.2RECOMMENDATIONS I. As securing internship placement is becoming difficult each year, I recommend that the institution/department recommend students for internship opportunities in organizations related to their course of study. II. The institution and Department should liaise closely with the industries relating to the study of the program to breach the gap between academic learnings and real-life applications by organizing short internships, workshops and seminars on the operations of the industry. 34 III. Research and Development is the bedrock on which ground breaking innovations and technologies are built upon, I suggest that students be fully engaged in the ongoing researches at the department/faculty level so as to help them obtain the skillset upon graduation. IV. The Industrial Training Fund should provide adequate and prompt means of fundings to students during the period of internship to ensure that the work experience is financially itch free. 35 REFERENCES 1. Fortis Engineering Services Limited Handbook. 2. Guide to Technical Report Writing Retrieved from https://www.sussex.ac.uk/ei/internal/forstudents/engineeringdesign/studyguides/techr eportwriting 3. History of SIWES (Student Industrial Work Experience Scheme) Retrieved from https://nigerianfinder.com/history-of-siwes/ 4. Smarter Remote non- intrusive Corrosion monitoring with installed ultrasonic sensors Retrieved from https://www.sensornetworkscorp.com/remote-non-intrusive-corrosionmonitoring/ 5. Writing an Engineering technical report Retrieved from https://www.monash.edu/rlo/assignment-samples/engineering/eng-writing-technicalreports 36 View publication stats