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NATIONAL INSTITUTE OF TRANSPORT

FACULTY OF TRANSPORT AND ENGINEERING TECHNOLOGY

DEPARTMENT OF AUTOMOTIVE AND MECHANICAL ENGINEERING

INDUSTRIAL PRACTICAL TRAINING REPORT (IPTU II)

FROM 29TH JULY 2024 TO 22TH SEPTEMBER 2024

STUDENT NAME: NGEME MALAGO

REGISTRATION NUMBER: NIT/BMEL/2021/1415

YEAR OF STUDY: 2023/2024

ORGANISATION: NYAKATO 60 MW POWER PLANT

PROGRAM NAME: HDME


ABSTRACT
Field practical training is an opportunity to relate what has been covered in class and what is
applicable in the field in an operational environment.

This field practical report consists of three chapter where by chapter one
consists of general introduction of Nyakato 60MW power plant and location,
historical background and Nyakato 60MW power plant organization structure.
Chapter two consist of description how to repair damaged cylinder liner and
chapter three consist of conclusion, page of reference, page of appendix and
recommendation.

Through this field practical training I faced some challenges and one major challenge I faced was
the material provided in order at workshop, this make most of students were observes how
supervisor perform different operation at work time without performing any operation.

Weekly report consists of briefly description of all wok which I have


performed at Nyakato 60MW power plant of all eight weeks. It includes
weekly description of the jobs for each day in every week, description of the
main job for every week and diagrams for several machines.

I kindly invite you to go through each part of report and surely you will be
interested with it.

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DECLARATION
I hereby declare that the report has been prepared by myself from my
practical training which was held at Nyakato 60MW power plant starting from
29 July 2024 to 22 September 2024 to fulfill the curricular requirement of
MECHANICAL ENGINEERING (HDME III) offered by Faculty of Transport
Engineering Technology in National Institute of Transport.

Supervisor name: JOSEPH MHINDI

Supervisor signature ……………………………

DATE …………………….

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ACKNOWLEDGEMENT
The completion of this report could not be possible without the participation
and assistance of so many people whose names not all may be
acknowledged but their contribution are sincerely appreciated and gratefully
acknowledged. I would like to express my deep appreciation and
indebtedness particularly to the following.

I would like to thank GOD for his wisdom and blessing which help me to
complete this field training in good health, peace and harmony, despite the
challenges I faced.

I express my deep sense of gratitude to The National Institute of Transport


(NIT) and Transport Engineering Technology Faculty.

I sincerely thank my industrial training supervisor Josph mhindi for his good
supervision, knowledge, skill, guidance and well-arranged time table.

I am very thankful to Human Resource Manager at Nyakato 60MW power


plant for her kindness and assistance during my Practical Training at Nyakato
60MW power plant.

Lastly, I would like to send my gratitude to people of Nyakato 60MW power


plant and my fellow student who were participating together in our Practical
Training at Nyakato 60MW power plant for their kindly for the whole time of
my field work.

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LIST OF ABBREVIATIONS
NIT -National Institutes of Transport

TET -Transport Engineering and Technology

TANESCO - Tanzania Electric Supply Company Limited

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TABLE OF CONTENTS
ABSTRACT.....................................................................................................................................i
DECLARATION.............................................................................................................................ii
ACKNOWLEDGEMENT..............................................................................................................iii
LIST OF ABBREVIATIONS.........................................................................................................iv
CHAPTER ONE............................................................................................................................1
1.0 INTRODUCTION.....................................................................................................................1
1.1 HISTORICAL BACKGROUND OF TANESCO.....................................................................1
1.2 FUCTIONS OF TANESCO.......................................................................................................2
1.3 ORGANIZATION STRUCTURE OF TANESCO....................................................................3
1.4 ORGANIZATION VISSION, MISSION, AND OBJECTIVES...............................................3
1.4.1 VISION...............................................................................................................................3
1.4.2 MISSION............................................................................................................................3
1.4.3 OBJECTIVES OF ORGANIZATION................................................................................3
CHAPTER TWO...........................................................................................................................5
2.0 REPAIRING OF CYLINDER LINER INTO CYLINDER BLOCK........................................5
2.2 OBJECTIVE OF THE PROJECT.............................................................................................8
2.3 PROBLEM FORMULATION...................................................................................................8
2.4 ANALYSIS SOLUTION...........................................................................................................8
2.5 DESIGN.....................................................................................................................................9
CHAPTER THREE.....................................................................................................................10
3.0 CONCLUSION AND RECOMMENDATION.......................................................................10

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3.1 CONCLUSION........................................................................................................................10
3.2 RECOMMENDATION...........................................................................................................10
REFERENCE...............................................................................................................................11

LIST OF FIGURES

Figure 1: TANESCO Organization Structure.................................................................................9


Figure 2: Cylinder liners...............................................................................................................11
Figure 3: Dry Cylinder liner.........................................................................................................12
Figure 4: Wet Cylinder liner.........................................................................................................12
Figure 5: Wear and Cracked cylinder liner...................................................................................13
Figure 6: Design flow chart for repairing of cylinder liner..........................................................15

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CHAPTER ONE

1.0 INTRODUCTION
The Nyakato plant is a Gas power plant located in Tanzania. Nyakato has a peak capacity of
63MW which is generated by Gas. The power plant was commissioned in 2012 and started
energy production the same year. The current owner and operator of the Nyakato facility is
Tanzania Electric Supply Company.

1.1 HISTORICAL BACKGROUND OF TANESCO


Tanzania Electric Supply Company Limited (TANESCO) is a Parastatal organization established
by Memorandum and Articles of Association incorporated on 26th November 1931 which
established Tanzania Electric Supply Company Limited (the then Tanganyika Electric Supply
Company Limited -TANESCO). The Company generates, purchases, transmits, distributes, and
sells electricity to Tanzania Mainland and sells bulk power to the Zanzibar Electricity
Corporation (ZECO), which in turn sells it to the public in islands Unguja and Pemba.
TANESCO owns most of the electricity generating, transmitting, and distributing facilities in
Tanzania Mainland with an estimated population of over 50 million.

Historically, the German colonialists established the first public electricity supply in Tanzania,
the then called Tanganyika in 1908 at Dar es Salaam. It served the railway workshops and a part
of the town where the colonialists were mostly staying. In 1920, when Tanganyika territory was
put under Great Britain protectorate, a Government Electricity Department was formed to take
over and operate the public supplies left by the Germans. In 1931, the Government handed over
the undertaking at Dar es Salaam and those elsewhere upcountry (Dodoma, Tabora, and Kigoma)
to private enterprises. One of these companies was the Tanganyika Electric Supply Company
Ltd. (TANESCO) and the other Company was the Dar es Salaam and District Electric Supply
Company Ltd (DARESCO). The two companies were merged in 1964 and later changed their
name into Tanzania Electric Supply Company (TANESCO).

Tanzania Development Vision 2025 envisages to make the Country the middle income by 2025,
this implies that GDP per Capita will be raised from USD 640 to at least USD 3,000 by 2025. To
achieve this target, we need fast economic growth which must be propelled by an adequate,

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reliable, affordable, and environmentally-friendly electricity supply. Therefore, Generation
capacity needs to be increased from 1,583 MW to at least 10,000 MW by 2025.

In undertaking its core functions TANESCO is guided by the National Energy Policy of 2003
and Electricity act of 2008. TANESCO Ltd functions under the regulatory guidance of the
Energy and Water Utilities Regulatory Authority (EWURA) established by the EWURA Act of
2001. In complying with the above directives, the Company has come up with a structure that
reduces operational costs without compromising performance and efficiency. It has also
considered the National Agenda for Industrialization that aims at transforming Tanzania’s
economy into middle income.

1.2 FUCTIONS OF TANESCO


i. To undertakes power generation activities through plants owned by TANESCO, both
National grid-connected and off-grid stations. Other sources of generation are from
independent power producers (IPPs) which feed the National Grid and isolated areas as
well as Small Power Producers (SPPs).
ii. To undertakes power transmission activities including operations and maintenance of the
power grid system. TANESCO owns an interconnected power grid made up of a
generation, transmission, and distribution system.

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1.3 ORGANIZATION STRUCTURE OF TANESCO

Figure 1: TANESCO Organization Structure

1.4 ORGANIZATION VISSION, MISSION, AND OBJECTIVES


1.4.1 VISION
Leading provider of energy solutions that drive sustainable economic prosperity in Africa.

1.4.2 MISSION
Deliver customer-focused energy solutions through investment in our people, innovation and
modernizing our infrastructure.

1.4.3 OBJECTIVES OF ORGANIZATION


i. To ensure that all legal matters are handled professionally and in a timely manner in the
best interest of the company.
ii. To prepare TANESCO standard contracts for use for all services within the company and
ensure that contracts are prepared and executed in accordance to standards.
iii. To ensure that the company complies with national and institutional principles of good
governance.

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iv. To support the company’s business objectives by ensuring the safety of company
properties, assets, installations, and systems through well planned and monitored actions
both internally and externally to ensure that company infrastructure and installations are
safeguarded.
v. To ensure compliance of the company security policy.

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CHAPTER TWO

2.0 REPAIRING OF CYLINDER LINER INTO CYLINDER BLOCK


The cylinder liner is a sleeve placed on the engine block bore to create a cylindrical design. The
engine piston moves back and forth in the cylinder liner. It is a vital part of the vehicle that
makes up the smooth internal side of the engine.

But cylinder liners are commonly used on engines with aluminum alloy engine blocks. This is
because the aluminum alloy engine block without a liner has poor wear resistance and may warp
at high temperatures. Therefore, linear is used for a better surface that can bear high temperatures
and pressures.

Figure 2: Cylinder liners

FUNCTION OF CYLINDER LINER


i. To provide a sliding surface for the motion of the piston. It acts as the internal wall of the
cylinder. It traps the lubricant.
ii. To reduce the engine temperature up to the optimal operating temperature through wet
liner transfers heat to the coolant, and the dry liner transfers heat directly to the engine
block.
iii. It provides excellent sealing and lessens the gas leak in compression and exhaust gases.
iv. The cylinder liner has the ability to bear high temperatures and pressures during
combustion, so the engine block is not heavily stressed.
v. A liner serves as a wear and tear protector to prevent the cylinder block from damage.

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TYPES OF CYLINDER LINERS
The cylinder liner has the following types:
i. Dry Liner
This type of cylinder liner has a shape like a barrel. It has a flange installed at the top. This
flange holds the liner in a similar position to the engine block. These liners don’t have direct
contact with the cooling water.

Figure 3: Dry Cylinder liner

ii. Wet Liner


In the wet liner, the liner makes contact with the cooling water or coolant. There is a flange
on top of the liner that fits into the groove in the cylinder block.
The wet liner has a wall thickness between 3mm and 6mm. The aluminum is used to coat the
external side of the liner. This coating is compulsory to prevent rust.

Figure 4: Wet Cylinder liner


iii. Finned Cylinder Liners
The finned cylinder liner has a very similar working to the dry liner, but it has sockets around
the outer surface to help with heat dissipation.

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2.1 PROCEDURES FOR REPAIRING OF CYLINDER LINER
i. Inspect the cylinder liner for wear, cracks, and any signs of damage. Use tools like a bore
gauge to measure the liner's diameter and check for out-of-roundness.

Figure 5: Wear and Cracked cylinder liner

ii. Remove any carbon deposits, oil, or debris from the cylinder liner and surrounding
components. Use solvents and wire brushes as necessary. Ensure the area is clean for
accurate assessment and repair.
iii. When the cylinder liner is worn or damaged, it may need to be honed or bored to restore
its dimensions. Use precision machining tools to ensure the liner meets the
manufacturer’s specifications.
iv. For cracks or significant damage, welding techniques may be employed to repair the
liner. In some cases, a patch may be used to cover small holes or cracks, ensuring it is
securely bonded and ground flush.
v. After repairs, reinstall the cylinder liner, ensuring proper alignment and fit. Use new
gaskets and seals as needed to prevent leaks. Follow manufacturer specifications for
torque settings.
vi. After the liner is installed, conduct a thorough engine test to verify that the repair is
effective. Check for proper compression, oil leaks, and overall engine performance to
ensure the repair was successful.

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2.2 OBJECTIVE OF THE PROJECT
i. To improve engine efficiency, power output, and fuel economy.
ii. To provide a durable and reliable repair that extends the lifespan of the engine without
incurring unnecessary costs.
iii. To prevents coolant and oil leaks, which can lead to engine overheating and lubrication
issues.
iv. To ensures proper sealing between the liner and piston, maintaining optimal compression
for efficient combustion.

2.3 PROBLEM FORMULATION


i. Cylinder liners suffer from corrosion, wear, and scoring due to poor lubrication or coolant
leaks. Assessing the extent of damage is crucial, and sometimes replacement may be
more feasible than repair.
ii. Misalignment of the cylinder liner that cause uneven wear, increased friction, and
ultimately engine failure.
iii. Cylinder liner have cracks from overheating or thermal stress.
iv. Decrease in engine power and difficulty starting the car, due to a damaged cylinder liner,
which can lead to poor compression in the affected cylinder.
v. Engine is consuming more oil than usual, which sign of wear or damage to the cylinder
liner, allowing oil to leak into the combustion chamber.
vi. Knocking or tapping sounds coming from the engine, indicate that the cylinder liner is
damaged, which may result in improper piston movement or contact with other engine
components.

2.4 ANALYSIS SOLUTION


i. Car must be goes to garage at least two times per mouth to Examine the liner for visible
cracks, scoring, or excessive wear. Look for signs of pitting or corrosion that may
indicate coolant leaks or overheating, and Check for any surface irregularities that could
affect sealing and lubrication.
ii. Use a micrometer or bore gauge to measure the liner's thickness. A reduction in thickness
can indicate excessive wear or overheating, which can lead to failure.

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iii. Review the operating temperature history of the engine. Frequent overheating can cause
warping or cracking, and Conduct pressure tests to check for leaks, which could indicate
damage to the liner or gasket failure.
iv. Analyze engine oil for metal particles that could indicate liner wear. High levels of iron
or other metal shavings can signal severe wear and necessitate further inspection.

2.5 DESIGN

Figure 6: Design flow chart for repairing of cylinder liner

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CHAPTER THREE

3.0 CONCLUSION AND RECOMMENDATION

3.1 CONCLUSION
The field practical exercise was mainly to enable me acquire practical skills and link the theory
to practice of the real work like carving different type of gears and to operate some machines. I
have been able to acquire practical skills like issuing of maintenance of different machine with
its importance, also the importance of wearing safety equipment when you’re in the workshop.
Through this practical training I come to realize that the concepts taught in the class is refracting
what is being practice in the real field, but what is needed is the experience of the concept and
other related issues.

3.2 RECOMMENDATION
Industrial practical training is very essential to students as it provides exposure to different works
and increase knowledge to student. I recommend that to National institute of Transport through
its respective department (TET) should provide more and relevant practical to students so as not
to face difficulties in their field training. To students, I argue to have more discipline when are in
their working places during their field training as it increases chance of learning. Student should
attend effectively the whole period of training. They should listen and learning carefully different
mechanism and relate with what learn in class. Lastly student should work more harder during
their industrial practical training.

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REFERENCE
Logbook

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