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Internship Overview
Internship Overview
During this industrial training, I worked under the Engine Research & Development division, specifically Testing Group 1 (TG1). The group is responsible for durability and reliability testing of large diesel engines used in marine and industrial applications.
My responsibilities mainly involved:
Electronics troubleshooting
Industrial electrical wiring
Signal cable installation and management
Electrical system integration for engine testing setups
Assisting technicians in mechanical and electrical maintenance tasks
This internship provided hands-on exposure to industrial electrical systems used in large-scale engine testing facilities.
Electronics Troubleshooting
Electronics Troubleshooting
One of the early tasks involved troubleshooting malfunctioning electronics equipment used in the company’s hatchery research facility.
The equipment included:
A malfunctioning computer motherboard
An air pump controller PCB
The troubleshooting process began with a visual inspection of the motherboard components to identify potential physical damage. Voltage measurements were taken using a multimeter to verify power distribution across the board.
Figure 1: Computer motherboard used for troubleshooting.
Testing revealed unstable voltage levels caused by a faulty capacitor affecting the motherboard’s power distribution.
After replacing the faulty component, the motherboard was powered on for testing. The system produced four short beeps, which indicated a memory error according to the motherboard’s POST beep code. The issue was resolved by reseating the RAM module, which restored normal system operation.
Figure 2: Air Pump Controller PCB
A similar diagnostic approach was used to troubleshoot the PCB controlling an air pump. The PCB was tested using a multimeter to measure:
Resistance of components
Continuity of circuit paths
Diode functionality
Testing revealed:
Irregular resistance values in several resistors
A damaged diode that failed to conduct current properly
The faulty components were replaced, restoring the functionality of the air pump system. However, the battery charging issue could not be fully resolved within the available time. This task provided practical experience in component-level electronics troubleshooting and circuit diagnostics.
Large Engine Assembly Assistance
Large Engine Assembly Assistance
Large diesel engines use flywheels to stabilize rotational motion and maintain smooth engine operation. The flywheel stores rotational energy during the power stroke and releases it during the other strokes, helping to reduce speed fluctuations and vibration in the engine. Proper installation and tightening of flywheel bolts are critical to ensure mechanical balance and prevent misalignment during high-load operation.
Figure 3: Flywheel Bolt Installation
During Week 3, I assisted technicians in the large engine testing block. One of the tasks involved tightening the flywheel bolts of a large diesel engine using a torque wrench to ensure proper mechanical balance.
The bolts were tightened according to specified torque requirements to ensure reliable engine operation. Each bolt was checked after the initial tightening to confirm that the specified torque levels were reached, providing confidence that the flywheel would perform reliably during engine operation. The proper installation of the flywheel helped in maintaining the mechanical balance of the engine, which is crucial for its smooth and efficient functioning
Another task involved cleaning engine components such as the crankcase window cover before reinstallation.
Figure 4: Crankcase Window Cover
Components like crankcase window cover must be properly cleaned before reinstallation. Removing rust, oil residue, and debris helps prevent contamination inside the engine and allows technicians to inspect internal components more clearly during maintenance or testing.
Diesel fuel was used as a cleaning solvent to remove rust and accumulated debris without damaging the metal surface. This work helped maintain engine reliability and ensured that internal components remained free from contamination.
Multi-Core Signal Cable Integration
Multi-Core Signal Cable Integration
A major electrical task during the internship was connecting two 8-meter, 50-core signal cables used for engine instrumentation systems.
Figure 5: 50-core signal cables prepared for connection.
Figure 6: Soldering the Cable.
The process involved several steps:
Stripping insulation to expose the copper conductors
Twisting corresponding wire cores together
Soldering the connections to ensure electrical continuity
Once the soldering was complete, the solder joints were inspected for any irregularities to ensure the connections were firm and clean. Next is applying the heat shrink tubes.
Figure 7: Completed Connections
The application of heat shrink tubing over the soldered connections provided an additional layer of insulation, effectively preventing short circuits and safeguarding the connections against physical damage. This method of wire connection was essential in maintaining a high level of electrical integrity, ensuring that no signal loss or interruptions occurred.
The continuity test, performed using a multimeter, confirmed that all connected core cables were functioning correctly, with no breaks or weak points in the circuit. The second round of testing further validated the success of the wiring connections. This approach of soldering, insulating, and testing ensured the reliability and durability of the electrical connections, making them suitable for long-term operation without risk of failure.
Signal Cable Shielding and Cable Management
Signal Cable Shielding and Cable Management
Signal cables used in engine testing systems carry measurement data from sensors such as temperature, pressure, and speed sensors to the control panels. These signals are typically low-voltage and therefore susceptible to electromagnetic interference (EMI) generated by nearby electrical equipment and power lines.
To reduce signal noise and ensure reliable data acquisition, the signal cables were wrapped with aluminium shielding tape, which acts as an electromagnetic barrier that blocks external interference.
After shielding was completed, the cables were routed through cable trunking systems to organize and protect the wiring. Proper cable management helps prevent mechanical damage, simplifies maintenance, and improves overall system reliability.
Figure 8: Signal cables shielded with aluminium tape.
Figure 9: Signal cables installed inside cable trunking.
Figure 10: Cable trunking installation from another angle.
Induction Motor Power Wiring
Induction Motor Power Wiring
Induction motors are widely used in industrial environments due to their durability and simple construction. During the internship, the power supply cable of an induction motor used in the research block needed to be extended.
Figure 11: Extending the supply cable of an induction motor.
Figure 12: Power cord connection.
The process involved stripping the insulation of a two-core power cable and connecting the conductors securely to the motor supply terminals. A power cord was then connected to the cable to allow the motor to be powered from a nearby electrical outlet. Before energizing the motor, electrical checks were performed using a multimeter to verify continuity and ensure that no short circuits were present. These verification steps are important to prevent electrical faults and equipment damage.
Terminal Crimping for Signal Connections
Terminal Crimping for Signal Connections
Signal cables used for instrumentation systems must be securely connected to terminal blocks to ensure reliable electrical connections. For this purpose, pin terminals were attached to the ends of the signal wires.
Figure 13: Crimped Wires
The insulation at the wire ends was first stripped to expose the copper conductor. The conductors were then inserted into the metal sleeve of the pin terminal. A crimping tool was used to compress the terminal onto the wire, creating a strong mechanical and electrical connection. Proper crimping ensures that the wire does not loosen due to vibration or repeated operation of the engine testing system.
Armoured Cable Installation
Armoured Cable Installation
Armoured cables are commonly used in industrial environments because they provide additional mechanical protection against physical damage. Without armour, even a minor incident can sever insulation, expose conductors, cause short circuits, arc faults, fires, or complete power loss. Which can leading to expensive downtime, safety hazards, or equipment damage.
Figure 14: Stripped Armoured Cable
During the installation process, the outer protective layer and armour were carefully removed to expose the internal conductors while ensuring that the insulation of the individual wires remained intact.
The process began by carefully removing the outer protective armour layer of the cable using appropriate stripping tools. Special care was taken to ensure that the stripping process did not damage the inner insulation or the copper conductors.
Any damage to the inner insulation could potentially lead to electrical faults or short circuits during operation. Once the armour was removed, the internal conductors were exposed and prepared for termination.
Figure 15: Stripped Armoured Cable
To further protect the exposed connections, heat shrink tubing was applied over the cable ends as shown in Figure 15. The heat shrink tubing was heated using a heat gun until it tightly wrapped around the cable insulation. This process provided additional electrical insulation and protected the connections from moisture, dust, and mechanical wear.
The use of heat shrink tubing is essential in industrial wiring because it enhances insulation reliability and prevents accidental contact between exposed conductive parts.
Panel Box Wiring and Continuity Testing
Panel Box Wiring and Continuity Testing
Panel boxes play an essential role in controlling and distributing electrical signals to various engine components. Proper wiring inside the panel box is critical because incorrect connections could result in malfunctioning control systems or potential electrical hazards.
Figure 16: Schematic diagram of the wire connections.
The wiring process began by studying the schematic diagram provided by the supervisor. The schematic diagram illustrated the correct wiring configuration between the terminals and components inside the panel box.
Each wire was identified according to its designated label and terminal number to ensure that the connections followed the specified electrical design. Each wire was carefully inserted into the correct terminal block and secured tightly to prevent loose connections.
Loose wiring can cause unstable electrical signals, overheating, or intermittent system failures. Therefore, attention was given to ensuring that all terminals were firmly fastened and arranged neatly inside the panel box.
Figure 17: Checking the continuity of the wires.
Once the wiring process was completed, a continuity test was conducted using a multimeter. The continuity testing process involved placing the multimeter probes at different points along the wiring path to verify that electrical current could flow continuously through the circuit.
If the multimeter produced a beep sound or displayed low resistance, it indicated that the circuit path was complete and properly connected. If no continuity was detected, the wiring connections would need to be rechecked and corrected.
The continuity testing confirmed that all wiring connections were correct and that there were no open circuits or faulty connections within the system. This verification step ensured that the electrical signals could flow properly through the control system without interruption.
As a result, the panel box was ready for operation and capable of supporting the electrical control requirements of the large engine system. The successful completion of the wiring and testing process demonstrated the importance of accurate schematic interpretation, proper cable termination, and systematic electrical testing in industrial electrical installations.
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